US20100136277A1 - Printing Stock For Use In Printing Composite Signs, Methods And Apparatus For Printing Such Signs, And Methods For Manufacturing Such Printing Stock - Google Patents

Abstract

Printing stock for use in making a sign that includes a face sheet and a backing sheet. The sign is formed, for example, by overlapping a plurality of face sub-sheets of the printing stock, with the face sub-sheets arranged in a pattern to form a desired image of the sign. The face sheet includes a printing surface for receiving ink and an adhesive surface for receiving the backing sheet. The face sheet includes a face cut forming a margin and the face sub-sheet such that at least a portion of the margin is separable from the face sub-sheet. The backing sheet may include a backing cut forming a border and a backing sub-sheet such that at least a portion of the border is separable from the backing sub-sheet so that at least a portion of the adhesive surface of the face sheet is exposable.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application is a divisional application of pending U.S. patent application Ser. No. 10/836,604, filed on May 1, 2004, entitled “Printing Stock For Use In Printing Composite Signs, Methods And Apparatus For Printing Such Signs, And Methods For Manufacturing Such Printing Stock” by Jerry G. Hodsdon, et al., which is incorporated by reference in its entirety herein.
BACKGROUND OF THE INVENTION
• The present invention relates printing stock for use in small-office, home-office (SOHO) or other printers. The present invention also relates to printing stock that includes adhesive, and to printing stock that is used to form signs or posters that, because of size, would not be able to be printed on a single sheet of printing stock.
• Signs and posters are commonly utilized for any number of reasons, for example, for announcing a birthday, the arrival of a baby, an outdoor event at a park, a meeting, and so on. In many cases, the sign or poster is of a large size, that is, larger than a piece of paper having a standard size such as A4, 8½×11 inches, or legal size. Accordingly, a person desiring to make a large-scale sign has a couple of options. One option is to have the sign made professionally. However, this may involve a cost and a turn-around time that is not acceptable to a person.
• Another option is to make the sign on a SOHO printer connected to a computer. To do so, a person needs to print out sections of the desired sign on a number of pieces of paper. Some SOHO printers cannot print over the entire extent of a sheet of paper (i.e., the edges of the paper are left blank), so a person may need to cut off the unprinted edges by hand and then assemble the remainder of the printed sheets together by abutting or overlapping them to form the sign. The assembled sheets then need to taped or otherwise adhered together. Available software can manipulate images so that partial images may be printed on a SOHO print, and then assembled by overlapping or abutting the individual sheets of stock.
• One specific example of a conventional approach to printing large-scale signs on general-use printers is disclosed in U.S. Pat. No. 6,187,405 to Rudin. The Rudin patent shows two embodiments. One of the embodiments utilizes a sheet with a central image area defined by die cuts. The central image area is printed upon so the image edges align with the die cuts. The central image area is then removed from the sheet to form a sign.
• In the other embodiment, a repositionable sheet has a strip of adhesive applied along a top edge and a bottom edge of the paper. The central image area is then printed upon and then removed from the sheet to form a sign. Without adhesive in a middle portion thereof, the central image area may be moved about when assembling a sign or a banner. However, in either embodiment of the Rudin patent, a user needs to position a plurality of sheets in such a way that adjacent edges of abutting sheets are precisely aligned in order to have whatever graphic or image is printed on the central image areas look presentable. Moreover, the Rudin patent discusses an extensive and time-consuming test-printing process whereby the user manually adjusts the print margins of the image so that the edges of the image precisely align with the die cuts around the central image area of the sheets.
• While the above options may have cost advantages over professionally made signs, there are drawbacks. For example, a considerable amount of manual work needs to be employed to make the sign, particularly in ensuring that sheets are precisely printed and aligned, butting up against each other in a side-to-side arrangement. If there is any printer misregistration or skewing, then this cannot be compensated for, and the resulting images are likely to be misaligned when assembled. Moreover, if the printed image or graphic does not extend to the edges, then the user cannot align the sheets with the printed image but rather needs to “eyeball” or guess where to position adjacent sheets that form the sign.
• In addition, the manual cutting of the unprinted edges may result in an imperfect sign with breaks or gaps in the text or image of the sign. Further along these lines, if the sheets are not square for any reason (e.g., slight distortion of the central print area during removal from the sheet, inaccurate die cutting, etc.), then at least one of the abutting edges will not line up perfectly, thereby leaving a visible gap between sheets. In addition, any shrinkage in the sheets caused by low humidity may cause gaps to form between adjacent sheets. The printing described in the Rudin patent has precise printer page alignment that may not be reliably repeated on each printed page. Finally, old tractor-feed printers could print large rectangular banners; however, the banners were generally of poor quality and limited in height by the standard size of paper utilized by tractor-feed printers.
• Accordingly, there is a need for a printing stock and a related system that easily allow a user to print and assemble larger assemblies of the printing stock to form large signs, posters, banners, or the like. The present invention satisfies this need.
BRIEF SUMMARY OF THE INVENTION
• The present invention relates to printing stock and a system for printing and forming larger assemblies suitable for displaying a sign or the like. The invention also relates to methods and apparatus for utilizing such printing stock in making signs and to methods for manufacturing such printing stock.
• According to one embodiment of the invention and by way of example only, printing stock for use in making a sign includes a face sheet and a backing sheet. The sign is formed from a plurality of sheets of the printing stock, with the sheets arranged in a pattern to form a desired image of the sign. In a number of embodiments, the sheets of printing stock may be received through and printed on by a small-office, home-office (SOHO) printer. In other embodiments, the sheets of printing stock are of standard size for use with SOHO printers, i.e., A4, 8½×11 inches, and legal size. Accordingly, in these embodiments large-scale signs may be made efficiently and easily on a SOHO system.
• According to one aspect of the invention, the face sheet includes a printing surface for receiving ink and an adhesive surface for receiving the backing sheet. The face includes a face cut forming a margin and a face sub-sheet such that at least a portion of the margin is separable from the face sub-sheet. The backing sheet may include a backing cut forming a border and a backing sub-sheet such that at least a portion of the border is separable from the backing sub-sheet so that at least a portion of the adhesive surface of the face sheet is exposable.
• According to another aspect of the invention, the face may include a plurality of registration marks for enabling the face sub-sheet from one sheet of printing stock that is separated from at least a portion of the margin thereof to be positioned with respect to the face sub-sheet from another sheet of printing stock. Embodiments including registration marks carry the advantage of facilitating the alignment of adjacent sheets of printing stock when forming a composite sign.
• In a number of embodiments, the sheets of printing stock may be configured so that a sign may be formed on a surface. In other embodiments, the sheets of printing stock may be configured to form a sign without the need of a dedicated surface; that is, the sheets or portions of the sheets are adhered together. In still other embodiments, a carrier may be provided to which the sheets of printing stock may be applied.
• According to still another aspect of the invention, a system for making a sign may include a plurality of sheets of printing stock, a computer with a software program, and a printer. The computer may be configured to process an image into a plurality of sub-images for printing on a corresponding plurality of sheets of printing stock.
• In yet another embodiment, printing stock for use in making a sign may include a face sheet and a backing sheet. The face sheet may include a printing surface, an adhesive surface, and a face cut forming a margin and a face sub-sheet. The backing sheet may include a backing cut forming a border and a backing sub-sheet. The backing cut may be form so that when the face sub-sheet is removed, there is a relatively large exposed adhesive portion along one of the sides, with relatively small exposed adhesive portions along the other sides. In addition, sections of the backing cut may extend spatially beyond the face cut to be juxtaposed over the margin of the face sheet, thereby forming one or more tab sections of the backing sub-sheet for facilitating the removal of the backing sub-sheet from the face sub-sheet.
• Other features and advantages of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
• FIG. 1 illustrates a computer and printer system for making a sign with a plurality of sheets of printing stock;
• FIG. 2 is a perspective view of a sign with a composite image made according to a number of embodiments;
• FIG. 3 is a plan view of a face sheet of a sheet of printing stock with a sub-image printed thereon according to a number of embodiments;
• FIG. 4 is a view similar toFIG. 3 with a face sub-sheet peeled away to expose a portion of an adhesive surface thereof;
• FIG. 5 is a cross-sectional view taken along line5-5 ofFIG. 3;
• FIG. 6 is a plan view of a face sheet of a sheet of printing stock with a sub-image printed thereon according to a number of other embodiments;
• FIG. 7 is a cross-sectional view taken along line7-7 ofFIG. 6;
• FIG. 8 is a plan view of a backing sheet of the sheet of printing stock ofFIG. 6;
• FIG. 9 is a view similar toFIG. 6 with a combination of a margin and a border removed;
• FIG. 10 is a cross-sectional view taken along line10-10 ofFIG. 9;
• FIG. 11 is a plan view of the sheet ofFIG. 9 aligned with a sheet of printing stock with a corresponding sub-image;
• FIG. 12 is a view similar toFIG. 11 with the two sheets adhered together;
• FIG. 13 is a plan view of a face sheet of a sheet of printing stock with a sub-image printed thereon according to a number of still other embodiments;
• FIG. 14 is a view similar toFIG. 13 illustrating a face sub-sheet removed from the sheet of printing stock and adhered to a surface;
• FIG. 15 is an enlarged fragmentary view of a corner of a sheet of printing stock with registration marks according to some of the embodiments;
• FIG. 16 is a view similar toFIG. 14 illustrating another sheet being align with a sheet already adhered to a surface;
• FIG. 17 is a view similar toFIG. 16 illustrating the two sheets align and adhered to the surface;
• FIG. 18 is an enlarged fragmentary view of a corner of a sheet of printing stock with registration marks according to other embodiments;
• FIG. 19 is an enlarged fragmentary view of a corner of a sheet of printing stock with registration marks according to still other embodiments;
• FIG. 20 is a block diagram illustrating a computer and printer system for processing and printing an image according to a number of embodiments;
• FIG. 21 is a flow chart illustrating computer methodology according to a number of embodiments;
• FIG. 22 schematically illustrates a software engine according to a number of embodiments;
• FIG. 23 illustrates a sign characterized by verticality;
• FIG. 24 illustrates a sign characterized by horizontality;
• FIG. 25 illustrates a sign characterized by rectangularity;
• FIG. 26 is a flow chart illustrating user methodology according to a number of embodiments;
• FIG. 27 is a flow chart illustrating manufacturing methodology according to a number of embodiments;
• FIG. 28 is a perspective view of a roll of uncut printing stock;
• FIG. 28A is a plan view of a sheet of printing stock according to a number of still other embodiments;
• FIG. 29 is a plan view of a sheet of printing stock according to still other embodiments;
• FIG. 30 is a cross-sectional view of a projection of a backing sub-sheet peeling away from a face sub-sheet;
• FIG. 31 is a plan view of a front side of a sheet of printing stock according to still further embodiments;
• FIG. 32 is a plan view of a back side of the sheet ofFIG. 31;
• FIGS. 33A to 33H illustrate methodology for applying a face sub-sheet of the sheet of printing stock shown inFIGS. 31 and 32 to a surface according to some of the embodiments;
• FIG.33D′ is a plan view of a back side of the readily adherent face sub-sheet shown inFIG. 33D;
• FIG. 34 is a plan view of a front side of a sheet of printing stock according to still other embodiments;
• FIG. 35 is a plan view of a back side of the sheet of printing stock ofFIG. 34;
• FIG. 36 is an enlarged fragmentary view of a tab section of a backing sub-sheet of the sheet of printing stock ofFIGS. 34 and 35;
• FIGS. 37A to 37H illustrate methodology for applying a face sub-sheet of the sheet of printing stock shown inFIGS. 34 and 35 to a surface according to some of the embodiments;
• FIG.37D′ is a plan view of a back side of the readily adherent face sub-sheet shown inFIG. 37D;
• FIG. 38 is a plan view of a front side of a sheet of printing stock according to still further embodiments;
• FIG. 39 is an enlarged fragmentary view of a corner of the sheet of printing stock ofFIG. 38 showing registration marks;
• FIG. 40 is a plan view of a front side of a sheet of printing stock according to other embodiments;
• FIG. 41 is an enlarged fragmentary view of a corner of the sheet of printing stock ofFIG. 40 showing registration marks;
• FIG. 42 is a plan view of a front side of a sheet of printing stock according to still more embodiments;
• FIG. 43 is an enlarged fragmentary view of a corner of the sheet of printing stock ofFIG. 42 showing registration marks;
• FIG. 44 is a plan view of a front side of a sheet of printing stock according to a number of embodiments;
• FIG. 45 is a plan view of a back side of a readily adherent sheet of printing stock illustrating exposed adhesive portions;
• FIG. 46 is a fragmentary cross-sectional view of the readily adherent sheet ofFIG. 45;
• FIG. 47 is a plan view of a front side of a sheet of printing stock according to further embodiments;
• FIG. 48 is a plan view of a front side of a sheet of printing stock according to still further embodiments; and
• FIG. 49 is a plan view of a back side of a readily adherent sheet removed from the sheet of print stock ofFIG. 48.
DETAILED DESCRIPTION OF THE INVENTION
• Referring more particularly toFIGS. 1 and 2 of the drawings, animproved system100 for printing asign102 may include acomputer104, aprinter106, and a plurality ofsheets108 of printing stock. Thesystem100 may be utilized when it is desired to print a large sign that is, a sign larger than a single standard-sized sheet of paper (e.g., A4, 8½×11 inches, or legal size) —with a standard small-office, home-office (SOHO) or home printer such as an inkjet printer or a laser printer.
• For the purposes of this description, thesign102 includes a printedcomposite image110 comprised of a plurality of printedsub-images112a,112b, . . . ,112n. Thecomposite image110 is represented by “AVERY” inFIG. 2, with each of the sub-images112 including a respective portion of “AVERY”, which will be discussed in detail below.
• ReferencingFIGS. 3,4, and5, eachsheet108 of printing stock may include aface sheet114 and abacking sheet116. Theface sheet114 may include aprinting surface118 for receiving ink and anadhesive surface120 for receiving thebacking sheet116. Theadhesive surface120 is particularly shown inFIG. 4. In some of embodiments, theadhesive surface120 of theface sheet108 may include a layer of adhesive122 applied to aback surface124 of theface sheet114 as shown inFIG. 5. As known in the art, thebacking sheet116 may include a release agent (not shown) coated on the side adherent to theadhesive surface120 of theface sheet108 to provide a suitable adhesive bond between thebacking sheet116 and theface sheet114.
• Theface sheet114 may also include aface cut126 that forms or defines amargin128 and aface sub-sheet130. The face cut126 is formed in theface sheet114 such that theface sub-sheet130 is separable from themargin128, as particularly shown inFIG. 4. That is, theface sub-sheet130 may be removed from thesheet108 of printing stock. The face cut126 may include a die cut formed through theface sheet114 as shown inFIG. 5. Alternatively, the face cut126 may include perforations, such as microperforations.
• According to a number of embodiments, thebacking sheet116 may include abacking cut132, which is shown in phantom line inFIGS. 3 and 4, that forms or defines aborder134 and abacking sub-sheet136, which are shown inFIGS. 4 and 5. The backing cut132 is formed in thebacking sheet116 such that thebacking sub-sheet136 is separable from theborder134 as shown inFIG. 4. In some of the embodiments, thebacking sub-sheet136 is removed from thesheet108 of printing stock when theface sub-sheet130 is removed from thesheet108 by remaining adhered to theadhesive surface120 of theface sub-sheet130.
• In the embodiment shown inFIGS. 3-5, the face cut126 may be positioned in theface sheet114 such that when theface sub-sheet130 is separated from themargin128, a portion of theadhesive surface120 is exposed, which portion is indicated byreference numeral138 inFIG. 4. For example, the face cut126 may be spatially positioned between the backing cut132 and aperimeter140 of theface sheet114 and thebacking sheet116. Also in the embodiment shown, the face cut126 may be generally rectilinear such that theface sub-sheet130 is rectangular.
• In some of the embodiments, the face cut126 and the backing cut132 may be substantially concentric about a central region of thesheet108 of printing stock. As a specific example for a standard-sized sheet108 of printing stock (e.g., 8½×11 inches), the face cut126 may be positioned equidistantly about three-eighths of an inch or so from theperimeter140, which the backing cut132 may be positioned equidistantly about one inch or so from theperimeter140.
• As known in the art, one of the effects of removing an adhesive label from a release liner or backing sheet is that the act of removing the label causes the label to curl. That is, the label bends where the adhesive is in the process of being separated from the liner. The result is similar to pulling a piece of paper with tension over an edge of a desk. Typically, the greater the adhesive strength, the greater the removal angle, or the thinner the label, the greater the curl will be. However, one of the advantages of this embodiment is that curl is reduced or eliminated. More specifically, as only aportion138 of theadhesive surface120 is exposed, less force is required to remove theface sub-sheet130. In addition, the presence of thebacking sub-sheet136 renders the removedface sub-sheet120 as a two-layer construction with greater stiffness, thereby bending less during and after removal from themargin128 and theborder134. The removal ofbacking sub-sheet136 also causes less of theface sub-sheet130 to be separated from theborder134 of thebacking sheet116.
• According to other embodiments, such as shown inFIGS. 6 and 7, the face cut126 may include four edge cuts142. For the purposes of this description, theface sheet114 and thebacking sheet116 each has (or collectively have) atop edge144a, abottom edge144b, and twoside edges144cand144d, with respective pairs of theedges144 intersecting at fourcorners146a,146b,146c, and146d. The edge cuts142 may each extend between a respective pair of opposingedges144 at a distance from a respective one of the edges. Accordingly, in these embodiments, the edge cuts142 divide themargin128 into a plurality ofmargin segments148a,148b,148c, and148d, with each margin segment148 being individually separable from the other margin segments148. In other words, at least a portion of themargin128 may be selectively separated from the other portions of themargin128.
• More specifically, in the embodiment shown, edge cut142aextends between the side edges144cand144dat a distance from thetop edge144a, thereby definingmargin segment148a; edge cut142bextends between the side edges144cand144dat a distance from thebottom edge144b, thereby defining margin segment148b; edge cut142cextends between thetop edge144aand thebottom edge144bat a distance from theleft side edge144c, thereby definingmargin segment148c; and edge cut142dextends between thetop edge144aand thebottom edge144bat a distance from theright side edge144d, thereby definingmargin segment148d.
• In some of the embodiments, thebacking sheet116 may include a plurality of pairs ofcorner cuts150aand150b, with each of the corner cuts150 extending from the backing cut132 to a respective one of theedges144 of thebacking sheet116, which are shown in phantom line inFIG. 6. Accordingly, in these embodiments, the corner cuts150 divide theborder134 into a plurality ofborder segments152a,152b,152c, and152d, which are particularly shown inFIG. 8, with each border segment152 being individually separable from the other border segments152. In other words, at least a portion of theborder134 may be selectively separated from the other portions of theborder134.
• To remove one of the border segments152, such asborder segment152das shown inFIGS. 6 and 9,border segment152ais peeled rearward away along corner cut150aatcorner146b, the backing cut132 alongedge144d, and corner cut150aatcorner146c.Margin segment148dalso peels away from theface sub-sheet130 along edge cut142d. The combination ofmargin segment148dandborder segment152dis then separated from the remainder of thesheet108 of printing stock as shown inFIG. 9, thereby leaving a portion of theadhesive surface120 exposed, which portion is indicated byreference numeral138 inFIG. 10. The removal of the combination ofmargin segment148dand border segment152 from thesheet108 of printing stock yields a readily adherent sheet of printing stock, which is indicated byreference number108′ inFIG. 9.
• Thesheets108 of printing stock configured according to the embodiment shown inFIGS. 6-10 may be utilized in making asign102 that does not-require adhesion to a surface to which theface sub-sheets130 are adhered. More specifically, with reference toFIGS. 11 and 12, asheet108aof printing stock with sub-image112aprinted on theface sheet130 thereof has not had any of the margin segments148 or the border segments152 removed and, accordingly, has not had any portion of theadhesive surface120 exposed. A readilyadherent sheet108b′ of printing stock withsub-image112bprinted on theface sheet130 thereof may then be adhered to theface sheet130 ofnon-adherent sheet108aso that the desired printedcomposite image110 is formed.Sheet108b′ may be positioned onsheet108asuch that the exposedportion138 of the adhesive surface ofsheet108b′ is coextensive with a corresponding portion of theface sheet130 ofsheet108a. Accordingly, the resultingsign102 does not have any exposed portions of adhesive surface.
• Another one of the advantages of the embodiment shown inFIGS. 6-12 is that thesign102 may be adhered to a surface after assembly if desired. For example, a portion of the border segment152 may be removed to expose aportion138 of theadhesive surface120. Alternatively, all of the border segments152 along the perimeter of thesign102 may be removed for adhering to a surface. Still alternatively, all of thebacking sheet116 may be removed from thesign102 to expose the entireadhesive surface120.
• According to still other embodiments, such as shown inFIGS. 13 and 14, theface sheet114 may include aface cut126, while thebacking sheet116 is free of any backing cut. Accordingly, when removed from thesheet108 of printing stock, theface sub-sheet130 is separated from theentire backing sheet116 and themargin128 as shown inFIG. 14, with the entire extent of theadhesive surface120 of theface sub-sheet130 being exposed. In a number of embodiments, theface sheet114 may include one ormore registration marks154 that may be utilized in assembling the plurality ofsheets108 of printing stock that have been printed on to form thesign102.
• For example, with reference toFIGS. 13,14, and15, theface sheet114 may include a plurality of registration marks154. In the embodiments shown in these figures, the registration marks154 may be disposed at or near each of the fourcorners146 of theface sheet114. In other embodiments, the registration marks154 may be disposed near the face cut126 and any location along the extent thereof, for example, as indicated byreference numeral154ainFIG. 13. One of the advantages of utilizingregistration marks154 is that a user is enabled to quickly and accurately arrange, position, or alignadjacent sub-sheets130 to form a sign, which is discussed in more detail below. This is particularly useful when the printed image or graphic does not extend all the way to the edge of the sub-sheet130, in that a user may utilize the registration marks154 to alignadjacent sub-sheets130.
• As mentioned, the registration marks154 may be used during the assembly of thesign102. More specifically, the registration marks154 may aid, guide, or enable theface sub-sheet130 from one of thesheets108 of printing stock that is separated from themargin128 thereof to be positioned on a surface with respect to aface sub-sheet130 from another one of thesheets108 of printing stock that is already adhered to the surface. For example, as shown inFIG. 16, aface sub-sheet130awith a printed sub-image112ais adhered to asurface155. Asubsequent face sub-sheet130bwith a complementary printed sub-image112bmay then be positioned adjacent to, coextensively or overlapping along a common edge with, or in an otherwise composite relationship with the already adheredface sub-sheet130a, with thesubsequent face sub-sheet130bthen being adhered to thesurface155, such that the desired printedcomposite image110 is formed, as shown inFIG. 17.
• This desired or predetermined position may be attained by aligning anedge156 of the subsequently adheredface sub-sheet130bwith the registration marks154aof the already adheredface sub-sheet130a. Thereafter, adjustments may be made if needed to further align the printed image or text to compensate as needed for printer variation, mis-registration, and/or skewing. In this regard, in some of the embodiments, the registration marks154 may include one or more alignment elements158 respectively disposed substantially parallel to one of theedges144 of theface sheet114 or one of theedges156 of theface sub-sheet130, which is particularly shown inFIGS. 15 and 18. For example,alignment mark158ais substantially parallel to edge156dof the face sub-sheet130 (and edge144dof the face sheet114), andalignment mark158bis substantially parallel to edge156aof the face sub-sheet130 (and edge144aof the face sheet114). Accordingly, as represented inFIGS. 16 and 17, the registration marks154 enable aface sub-sheet130bthat is to be subsequently positioned to be overlapped on top of an already positioned face sub-sheet130a, and then to be moved to make adjustments as needed to more properly align theimage112 to compensate for minor mis-registration or skewing.
• In some of the embodiments, the registration marks154 may include a pair of alignment elements158, such as shown inFIG. 18. In other embodiments, the registration marks154 may include a plurality of alignment elements158 disposed in a cross-hair pattern, such as shown inFIG. 15. In still other embodiments, such as shown inFIG. 19, the registration marks154 may include adirectional element160aand160bdisposed near a respective one thealignment elements158aand158b, with the direction elements160 indicating a directional positioning of a subsequently adheredface sub-sheet130.
• As shown in the embodiments inFIGS. 15 and 18, the registration marks154 may be disposed on theface sub-sheet130 of theface sheet114. Alternatively, as shown inFIG. 19, the registration marks154 may be disposed on themargin128 of theface sheet114. In some of the embodiments, the alignment elements158 may be disposed equidistantly from a respective pair of edges156 (or144) at one of the corners146 (e.g.,alignment elements158aand158bdisposed equidistantly fromedges156dand156aatcorner146b). In addition, the registration marks154 may include perforations or may be die cut into theface sheet114. Alternatively, the registration marks154 may be applied to theprinting surface118 when the sub-image112 is applied to theprinting surface118, which will be discussed in more detail below.
• With reference toFIGS. 20 and 21, in a number of embodiments, thecomputer104 may be configured to process adigital image164 into a plurality of digital sub-images164 (step S100). Accordingly, thecomputer104 may then cause theprinter106 to print the plurality of sub-images164 (step S102) on a respective plurality ofsheets108 of printing stock (seeFIG. 1). Accordingly, with further reference toFIG. 2, when the face sub-sheets130a,130b, . . . ,130nof the respective plurality ofsheets108 of printing stock are arranged in a predetermined pattern, thesign102 is formed. Thesign102 includes the printedsub-images112a,112b, . . . ,112narranged in the desired composite printedimage102 corresponding to the originally processedimage162.
• In some of the embodiment, a software program may be loaded onto the computer in amemory166 for execution by aprocessor167. The software may process theimage162 to generate one or more sets ofdigital sub-images164 that may be appropriately used to form thesign102. More specifically, with reference toFIG. 22, asoftware engine168 according to a number of embodiments may process theimage162 to determine a layout of the image (step S106). For example, the layout of theimage162 may be characterized by being linear (e.g., horizontally or vertically), irregular (e.g., square, circular, or triangular), or text only. For the purposes of this description, the word “image” is used to indicate any type of output that may be printed on thesheets108 of printing stock, including images, graphics, text, or any combination thereof. Accordingly, if theimage162 contains only text, then thesoftware engine168 may determine that theimage162 may be linear (e.g., no wrapping of text) or rectangular (e.g., wrapping of text).
• Thesoftware engine168 may also process theimage162 to determine a configuration of the image (step S106). For example, the configuration of theimage162 may be characterized by being horizontal (e.g., unwrapped text), vertical, or rectangular. If theimage162 is characterized by verticality, then thesoftware engine168 may determine that the plurality offace sub-sheets130 with thesub-images112 should be arranged in a vertical pattern as shown inFIG. 23 to form thesign102. Further, if theimage162 is characterized by horizontality, then thesoftware engine168 may determine that the plurality offace sub-sheets130 with thesub-images112 should be arranged in a horizontal pattern as shown inFIG. 24 to form thesign102. In addition, Further, if theimage162 is characterized by rectangularity, then thesoftware engine168 may determine that the plurality offace sub-sheets130 with thesub-images112 should be arranged in a rectangular pattern as shown inFIG. 25 to form thesign102.
• In other embodiments, thesoftware engine168 may process theimage162 in consideration of size (step S108). To do so, a user may enter a desired size in thecomputer104 through a user interface170 (seeFIG. 1), for example, x feet by y feet, such that the printedimage110 is characterized by size.
• Thesoftware engine168 may then utilize these characteristics of theimage162 and the desired printedimage110 to determine one ormore sets172 ofdigital sub-images164 that may be appropriately used to form thesign102 in a print engine (step S110). For example, thesoftware engine168 may determine the number ofsheets108 of printing stock that are required to form asign102 with the desired printedimage110. In addition, thesoftware engine168 may determine a layout of each of the sub-images112 on theface sheet130 to achieve the desiredcomposite image110. If more than one set172 of digital sub-images will satisfactorily form thecomposite image110, then thesoftware engine168 may query a user through theinterface170 whichexemplary set172 to use. The selected or mostappropriate set172 ofdigital sub-images164 may then be output to aprint driver174.
• In some of the embodiments, thesoftware engine168 may determine an overlap inadjacent sub-images112 so that when theface sub-sheets130 are arranged in the predetermined pattern to form the sign, there will be no breaks in thecomposite image110. More specifically, as shown inFIG. 11, sub-image112aofsheet108amay include anoverlap176aalong the side ofsheet108athat will be adjacent to or mated withsheet108b′. Similarly, sub-image112bofsheet108b′ may include anoverlap176aalong the side ofsheet108b′ that will be adjacent to or mated withsheet108a. Accordingly, as shown inFIG. 12, whensheet108b′ is adhered tosheet108a,overlap176boverlays and aligns withoverlap176aso that the resultingcomposite image110 is complete and without breaks. Anoverlap176 is also illustrated inFIGS. 3 and 13. The overlapping of thesheets108 may compensate for and enable correct alignment when minor variations in print registration and minor skewing of the image or text are present on thesheets108.
• Referring toFIG. 2, according to a number of embodiments, a kit for making a sign may include a plurality of thesheets108 of printing stock. In addition, the kit may include acarrier176 on which theadhesive surface120 of theface sheets130 is adherent. In some of the embodiments, thecarrier176 may include a releasably adherent adhesive or, alternatively, anapplication surface178 that is releasably adherent with theadhesive surface120 of theface sheets130, so that thecarrier176 may be used repeatedly for subsequently produced signs. Further, the kit may include aneasel180 for holding thecarrier176. In another embodiment, thecarrier176 may have an adhesive surface to which non-adhesive sheets having a weakening line forming a margin and a face sub-sheet may be releasably adhered.
• ReferencingFIG. 26, to make thesign102 from a user's point of view may include providing a plurality ofsheets108 of printing stock (step S112). The user may then select or create a desiredimage162 for thesign102, for example, through theuser interface170. The user may then print the sub-images112 on a respective plurality of thesheets108 of printing stock (step S114). The user may then expose a portion (e.g.,portion138 inFIG. 4) of the adhesive surface120 (step S116) by, for example, removing at least a portion of theborder134 of thebacking sheet116. The user may then form the sign102 (step S118) by adhering the exposedportion138 of theadhesive surface120 to theprinting surface128 of theface sheet114 of another one of the printedsheets108 of printing stock such that the sub-images112 form thecomposite image110. In embodiments where theface sheets130 includeregistration marks154, the user may align theface sheet130 with the exposedportion138 of theadhesive surface120 with the registration marks154 and the printed image or text of the another one of the printedsheets108 of printing stock.
• With reference toFIG. 27, from a production standpoint, thesheets108 of printing stock may be manufactured by first providing uncut printing stock (step S120), such as a roll ofprinting stock182 as shown inFIG. 28 including acontinuous face sheet114 andbacking sheet116. A plurality offace cuts126 may then be made through the face sheet114 (step S122) to form a plurality of themargins128 and a corresponding plurality of theface sub-sheets130. A plurality ofbacking cuts132 may then be made through the backing sheet116 (step S124) to form a plurality of theborders134 and a corresponding plurality of thebacking sub-sheets136. In addition, a plurality ofregistration marks154 may be made (step S126). In embodiments in which the registration marks are die cut, the registration marks154 may be made at the same time the face cuts126 are made (i.e., at step S122). The printing stock may then be cut into thesheets108 of printing stock (step S128) such that each of thesheets108 of printing stock includes a face cut and a backing cut. As mentioned, in a number of embodiments, thesheets108 are cut standard sizes (e.g., A4, 8½×11 inches, and legal size) to be receivable through a SOHO printer.
• Additional embodiments ofsheets108 of printing stock are illustrated inFIGS. 28A and 29. In the embodiments shown, thesheet108 may include abacking cut132 in the backing sheet116 (seeFIG. 5) such that abacking sub-sheet136 may include one ormore projections184. As shown in the embodiment ofFIG. 28, oneprojection184 may be formed in each opposing side of thebacking sub-sheet136. Alternatively, as shown in the embodiment ofFIG. 29, oneprojection184 may be formed in each of the four sides of thebacking sub-sheet136. Theprojections184 may be semi-circular as shown, or may be oval, elliptical, rectilinear, free form, or any other shape.
• When assembling asign102 with theborder134 removed from thebacking sheet116, theface sub-sheet130 with thebacking sub-sheet136 may be positioned on a surface155 (see, e.g.,FIG. 16) and aligned with one or more sheets already in place on the surface if such sheets are present. The exposed adhesive portion138 (see, e.g.,FIG. 4) along one side (e.g., the left side) may be adhered to both the adjoining already-mountedface sub-sheet130 and thesurface155.
• With reference toFIG. 30, the unadhered opposing side (e.g., the right side) may then be bent back toward theface sub-sheet130. Because of the stiffness of thebacking sub-sheet136 and the strength adhesive bond between theadhesive surface120 and thebacking sub-sheet136, theprojection184 may separate from theadhesive surface120 of theface sub-sheet130 as shown inFIG. 30, thereby providing a finger tab for grasping to facilitate the removal of thebacking sub-sheet136. In addition to this feature, theprojections184 may further provide a visual cue to a user to remove thebacking sub-sheet136 prior to adhering the entire exposedadhesive portion138 to the surface.
• With further reference toFIGS. 28 and 29, the backing cut132 may be made in thebacking sheet116 so that a relativelynarrow border134 is defined in thebacking sub-sheet116 along one or more sides, for example, a top and bottom side as shown inFIG. 28. In this regard, a relatively narrow exposedportion138 of theadhesive surface120 results when theborder134 is removed, as indicated by reference alpha t in these two figures, with a relatively small or narrow exposedportion138 resulting from the embodiment shown inFIG. 28, in comparison to a relatively large exposed portion resulting from the embodiment shown inFIG. 29 (and in comparison to a relatively large border indicated by alpha s inFIG. 28). The narrow exposedportion138 is preferably defined along the shorter sides, namely, the top and bottom sides, so that it is easier to fold back theface sub-sheet130 to remove thebacking sub-sheet136. Alternatively, thesheet108 may include anasymmetrical backing sub-sheet136 so that only a single narrowed exposedportion138 is defined along one of the sides. In some of the embodiments, the relatively narrow portion t indicated inFIG. 28 may be on the order of less than about one inch.
• With reference toFIG. 31, in still other embodiments asheet108 of printing stock may include aface sheet114 with a primary face cut126 defining theface sub-sheet130 and one or more secondary face cuts186 formed through themargin128 between the primary face cut126 and an outer edge of theface sheet114. In some of the embodiments, the secondary face cuts186 may be formed near the corners of theface sheet114, for example, positioned in the left andright margins128 and spaced from the top and bottom edges by less than a few inches. The secondary face cuts186 may be continuous cuts or, alternatively, may be perforated. The secondary face cuts186 may be described as defining atop margin128a, abottom margin128b, aleft margin128c, and aright margin128d.
• As shown inFIG. 32, thebacking sheet116 may include a primary backing cut132 defining thebacking sub-sheet136 and one or moresecondary backing cuts188 formed through theborder134 between the primary backing cut132 and an outer edge of thebacking sheet116. In some of the embodiments, thesecondary backing cuts188 may be formed near the corners of thebacking sheet116, for example, positioned in the left andright borders134 and spaced from the top and bottom edges by less than a few inches. Thesecondary backing cuts188 may be continuous cuts or perforated. Thesecondary backing cuts188 may be described as defining atop border134a, abottom border134b, aleft board134c, and aright border134d.
• As shown inFIG. 31 and described in more detail below, themargins128 and theborders134 define in thesheet108 atop section192a(including thetop margin128aand thetop border128b), a bottom section (including thebottom margin128band thebottom border134b), aleft side section192c(including theleft margin128cand theleft border128c), and aright side section192d(including theright margin128dand theright border134d).
• In a number of embodiments the primary face cut132 may include a plurality ofperforated sections190 indicated by dashed line inFIG. 32. Theperforated sections190 may be positioned along at least two of the four portions (i.e., top, bottom, left, and right) of the primary backing cut132, for example, along the left portion and the right portion of the primary backing cut132 as shown. Also as shown, the primary backing cut132 may include threeperforated sections190 per side and spaced substantially equidistantly. Theperforated sections190 may be described as providing a weakened bond between thebacking sub-sheet136 and theborder134 of thebacking sheet116.
• With continued reference toFIGS. 31 and 32 and additional reference toFIGS. 33A to 33H, after thesheet108 has been printed upon with a sub-image112 (not shown inFIG. 33A; see, e.g.,FIG. 3), the top andbottom section192aand192bmay be removed, for example, by peeling the sections192 rearward and away from theface sub-sheet130, as shown inFIG. 33B. One of theside sections192cor192d, e.g., theleft side section192c, may then be removed as shown inFIG. 33C, for example, by holding theface sub-sheet130 and thebacking sub-sheet136 together while pulling the side section192 away and breaking theperforated sections190, thereby yielding a readilyadherent sheet108′ as shown inFIG. 33D.
• As shown in FIG.33D′, with the removal of theleft side sections192c, the readilyadherent sheet108′ includes a relatively large exposedadhesive portion138′ indicated by cross hatching. And with the removal of the top andbottom sections192aand192b, the readilyadherent sheet108′ includes a relatively small exposedadhesive portion138″ indicated by contrasting cross hatching.
• As shown inFIG. 33E, the readilyadherent sheet108′ may then be adhered to asurface155. Ifother face sub-sheets130 have already been adhered to the surface155 (e.g., face sub-sheets130a,130b, and130cas shown inFIG. 33E), then the readilyadherent sheet108′ may be aligned therewith as described above, e.g. by overlappingface sub-sheet130donto the already positionedface sub-sheets130band130c. Theface sub-sheet130dmay then be adjusted in position if needed to correct for mis-registration in the image or graphics printed thereof.
• One of the sides, e.g., the left side as shown and including the relatively large exposedadhesive portion138′, may then be pressed down against thesurface155 and any adjoiningface sub-sheets130. The other side, e.g., the right side, may then be curled toward the adhered side as shown inFIG. 33F. Because of the relatively small exposedadhesive portions138″, theface sub-sheet130dpeels relatively easily away from thesurface155 and any adjacent adhered face sub-sheets, while the portion of theface sub-sheet130dcorresponding to the relatively large exposedadhesive portion138′ remains adhered. The remaining border, e.g., theright border128das shown, may then be peeled away from theface sub-sheet130d. In embodiments with theperforated sections190, the peeling of theright border128dwill also peel thebacking sub-sheet136 away as well because of the attachment provided by theperforated sections190, as shown inFIG. 33G. The face sub-sheet103dmay then be adhered to thesurface155, as shown inFIG. 33H.
• Further embodiments of asheet108 of printing stock are illustrated inFIGS. 34 and 35. In these embodiments, aface sheet114 may have aface cut126 defining amargin128 and aface sub-sheet130. Abacking sheet116 may have a primary backing cut132 defining aborder134 and abacking sub-sheet136. In addition, thebacking sheet116 may include one or moresecondary backing cuts194 extending from the primary backing cut132 into theborder134, thereby forming one ormore border sections196, for example aleft border section196aand aright border section196b. Thesecondary backing cuts194 may also define one ormore tab sections198 of theborder sections196 at locations at which thesecondary backing cuts194 extend spatially beyond the face cut126 and are juxtaposed over themargin128 of theface sheet114, as particularly shown inFIG. 36. In some of the embodiments, thesecondary backing cuts194 may include anangled section200 spatially positioned over the face cut126 for facilitating a non-tearing separation of thetab sections198 from theadhesive surface120 of theface sheet114, which is discussed in more detail below.
• With continued reference toFIGS. 34 and 35 and additional reference toFIGS. 37A to 37H, after thesheet108 has been printed upon with a sub-image112 (not shown inFIG. 37A; see, e.g.,FIG. 3), themargin128 and theboard128 may be may be separated from theface sub-sheet130 and thebacking sub-sheet136, thereby yielding a modifiedsheet108″, as shown inFIG. 37B. Either one of theborder sections196, e.g., theleft border section196aas shown inFIG. 37C, may be removed by peeling the border section away from theface sub-sheet130 and breaking theperforated sections190 if present, thereby yielding a readilyadherent sheet108′ as shown inFIG. 37D.
• As shown inFIG. 37E, the readilyadherent sheet108′ may then be adhered to asurface155. Ifother face sub-sheets130 have already been adhered to the surface155 (e.g., face sub-sheets130a,130b, and130cas shown inFIG. 37E), then the readilyadherent sheet108′ may be aligned therewith as described above. One of the sides, e.g., the left side as shown, may then be pressed down against thesurface155 and any adjoiningface sub-sheets130. The other side, e.g., the right side, may then be curled toward the adhered side as shown inFIG. 37F.
• As shown in FIG.37D′, with the removal of theleft border section196a, the readilyadherent sheet108′ includes a relatively large exposedadhesive portion138′ indicated by cross hatching. And with the removal of themargin128 and theborder134, the readilyadherent sheet108′ includes a relatively small exposedadhesive portion138″ indicated by contrasting cross hatching.
• The remaining border, e.g., theright border section196bas shown, may then be peeled away from theface sub-sheet130d. Because of the relatively small exposedadhesive portions138″, theface sub-sheet130dpeels relatively easily away from thesurface155 and any adjacent adhered face sub-sheets, while the portion of theface sub-sheet130dcorresponding to the relatively large exposedadhesive portion138′ remains adhered. Thetab sections198 provide a purchase on which to grasp to facilitate the peeling. Theangled section200 at thetab section194 facilitates a smooth peeling action at that location. In embodiments with theperforated sections190, the peeling of theright border section196bwill also peel thebacking sub-sheet136 away as well because of the attachment provided by theperforated sections190, as shown inFIG. 37G. The face sub-sheet103dmay then be adhered to thesurface155, as shown inFIG. 37H.
• Reference is now made toFIGS. 38 to 43 which respectively illustrate examples of additional embodiments ofprinting stock108, particularly embodiments ofprinting stock108 with different examples of registration marks154. More specifically, in the embodiments shown inFIGS. 38 and 39, the registration marks154 may include one or more alignment elements158 that are formed in theface sheet114 astabs202 that protrude outwardly from theedges156 of theface sub-sheet130. In other words, the alignment elements158 may be described as discontinuities in the face cut126 located at predetermined positions, such as less than an inch or so from a corner of the face sub-sheet130 (e.g., about three eighths of an inch). Accordingly, the alignment elements158 may be made at the same time or during the same production step as theface cut126. In alternative embodiments as represented inFIGS. 40 and 41, the alignment marks158 may be formed in theface sheet114 asnotches204 that protrude inwardly into theface sub-sheet130 from theedges156 thereof.
• Other examples of the registration marks154 are represented by the embodiments ofFIGS. 42 and 43. In these embodiments, the alignment elements158 may be formed in theface sheet114 asangled cuts206 that either project inwardly from theedges156 of theface sub-sheet130 or outwardly as shown. Accordingly, theangled cuts206 define discontinuities in the face cut126 and define anenlarged corner208 of theface sub-sheet130. Like the embodiments described above, as theangled cuts206 define a section of the face cut126, the registration marks154 of these embodiments may be made during production at the time theface sheet114 is cut into theface sub-sheet130 andmargin128. Regardless of the embodiment, the registration marks154 enable aface sub-sheet130 that is to be subsequently positioned to be overlapped on top of an already positionedface sub-sheet130, and then to be moved to make adjustments as needed to more properly align theimage112 to compensate for mis-registration or skewing.
• Reference is now made toFIGS. 44 and 45 in which are illustrated further embodiments of asheet108 of printing stock. In these embodiments, aface sheet114 may have aface cut126 defining amargin128 and aface sub-sheet130. Abacking sheet116 may have abacking cut132 defining aborder134 and abacking sub-sheet136. As shown, one or more sections of the backing cut132 may extend outwardly to form one ormore tab sections198. Eachtab section198 may extend spatially beyond the face cut126 to define anoverlay210 that is juxtaposed over themargin128 of theface sheet114, as highlighted by the cross hatching inFIG. 44.
• In a number of embodiments, the backing cut132 may be set apart spatially a relatively greater distance from one of the sides of the face cut126 (in the example shown, a top side of the face cut126). Accordingly, with the removal of theface sub-sheet130 along with the backing sub-sheet136 (i.e., the readilyadherent sheet108′) as shown inFIG. 45, a relatively large exposedadhesive portion138′ may be defined along one of the sides or edges of the readilyadherent sheet108′, while relatively small exposedadhesive portions138″ may be defined along the other sides or edges.
• With reference toFIG. 46, when positioned in a desired location on a surface156 (see also, e.g.,FIGS. 33E and 33F), the relatively large exposedadhesive portion138′ may be pressed down against thesurface156 to retain the readilyadherent sheet108′ in place. The remainder of thesheet108′ may then be lifted up to remove thebacking sub-sheet136, with theface sub-sheet130 thereafter being pressed and adhered to thesurface156.
• Alternatively embodiments ofsheets108 of printing stock are illustrated inFIGS. 47 and 48. Similar to the embodiment shown inFIG. 44, the backing cut132 may set apart spatially a relatively greater distance from one of the sides of theface cut126. In contrast to the prior embodiments, the backing cut132 may be spatially contained within the face cut126, i.e., there are not overlays210 (seeFIGS. 44 and 45). The backing cut132 may include indentations to provide an increased width of theborder134 indicated at A as shown inFIG. 47 or, alternatively, may be substantially rectangular or rectilinear in shape as shown inFIG. 48. In either embodiment, when the readilyadherent sheet108′ is removed as shown inFIG. 49, a relatively large exposedadhesive portion138′ may be defined along one of the sides or edges of the readilyadherent sheet108′ (represented by cross hatching), while relatively small exposedadhesive portions138″ may be defined along the other sides or edges (represented by opposing cross hatching).
• In addition to the embodiments illustrated in the drawings, the system includes any number of additional embodiments, modifications, and alternatives of thesheets108 of printing stock. For example, in some of the embodiments, thesheets108 may utilize discontinuous die cuts or perforations to define weakening lines on the four sides of theface sub-sheet130 andbacking sub-sheet136. In addition, theadhesive layer122 may be continuous or, alternatively, discontinuous. Further, thebacking sheet116 may be coextensive with theface sheet114, may cover only the area(s) of theface sheet114 with anadhesive surface120, or may cover both areas with adhesive122 and areas of theface sheet114 without adhesive.
• Still further, the face cut126 may include discontinuous die cuts or perforations to define asingle face sub-sheet130 therewithin as shown in, e.g.,FIGS. 3 and 4, or may include cuts that extend all the way to or close to the edges of theface sheet114. The face cut(s)126 may extend through theface sheet114 and theadhesive layer122 only, or may extend through theface sheet114, theadhesive layer122, and thebacking sheet116.
• The removal of the border sections of thebacking sheet116 may take place before or after removal of theface sub-sheet130 from thebacking sheet116. Alternately, theface sub-sheets130 may be independent and free of pressure-sensitive adhesive or a liner, with adhesive to attach the face sub-sheets to a surface or a carrier already applied on the surface of the carrier in the form of tape, pressure-sensitive adhesive with a liner, or water-based adhesive.
• In addition, adhesive may be supplied independently in the form of tape, paste, spray, or liquid. Tape or adhesive may also be applied to the face sub-sheets directly, either on a back surface or on a front surface, so that a secondary surface is not required for assembly of a sign. Alternately, theface sheet114 may have adhesive on the back side thereof that is not pressure sensitive but rather and water based, so that application of water to the adhesive activates the adhesive to enable bonding to a surface. Still alternately, double-sided tape may be applied to a back side of theface sheet114, either by the manufacturer or by the user, with a layer of backing sheet attached to the exposed side of the tape.
• In still other embodiments, double-sided tape may be in strips or may cover some or all of a back side of theface sub-sheet130 in continuous or discontinuous patterns. Alternatively, adhesive may be provided both on a back side of theface sub-sheet130 and on thesurface155 of a carrier such that the adhesive may be cohesive; namely, adhesives that do not bond to most other surfaces but do bond to a similar adhesive using pressure to bond the layers. Still alternatively, cohesive adhesives may be differently formulated but may form a unique bond when put in contact with one another under pressure.
• Further embodiments of thesheet108 may utilize a top layer of material which has a brittle layer bonded to a back side of the top layer. A face cut or a weakening line made through the top layer, either continuous or discontinuous, may define a perimeter of theface sub-sheet130. Bending the sheet at the weakening line may then fracture the brittle layer at the weakening line, creating a separation. Thesheet108 may be releasably bonded to a backing sheet with adhesive.
• In still further embodiments, thesheet108 may utilize a double-sided laminated assembly, that is: a first sheet of face material, an adhesive layer, a release agent, a liner sheet, a release agent on the other side of the liner sheet, another adhesive layer, and a second sheet of face material. The adhesive layer may be continuous or discontinuous, as described above. Alternately, the liner sheet may be eliminated, with each opposing sheet of face material having an alternating pattern of adhesive and release agent. The sheets of face material may be assembled so that the adhesive is in contact with the release agent on the opposing sheet, so that the sheets may be easily separated from one another without the use of a release liner and applied to a secondary surface. In either embodiment, the face cuts may be formed on both sides of the assembly as described above, or the face cuts may be discontinuous and through the entire assembly. The sheets of face material may be identical in substance and color or differently configured.
• In still other embodiments, asheet108 of printing stock may utilize a fan-folded or rolled continuous web of printable material (which is known in the art as banner material), with or without perforations between adjoining sheets to allow the web to be separated when so desired. The web of printable material may be a single layer or a laminate with a face material, an adhesive, and a release agent on a liner. In this way, larger images may have thesheets108 in a single row or column to be printed in a continuous stream, thereby eliminating the need for alignment of the sheets in one of the two directions in the larger image assembly. The fan-folded or rolled continuous web could have weakening lines or face cuts that are continuous or discontinuous along the length of the web on the right and left sides of the web, so that the unprinted area can be easily removed in preparation for assembly. The web may be a multilayer construction utilizing any of the variations described above, or the web may be a single-layer construction applied to a secondary surface as described above. The adhesive may also be applied separately as a double-back tape or as a liquid, or may be on the carrier or liner sheet.
• According to further embodiments, asheet108 of printing material may include a rectangular piece of printable face material with a removable adhesive bonded to a back side of the face material. The face material may be adhered to a second, larger rectangular piece of material in such a way as to have the adhesive preferentially adhere to the face material when the two layers are separated. Such an arrangement may be accomplished either by having an additional coating between the adhesive and the face that forms a stronger bond, by applying a release agent on the second layer of material, by the method of application, or by the inherent properties of the two materials themselves, such as differing surface tensions. The smaller rectangular top sheet may be positioned on top of the larger rectangular sheet in such a way as to provide a printable surface that may be printed upon past the edges of the sheet, which may be desirable for large sign assemblies. The second layer of material may be configured to absorb most or all of the ink that is applied beyond the edges of the face material, thereby allowing the ink to dry (ink-jet ink normally beads up and form pools of liquid ink if applied to the release side of a typical release liner). The assembly of the sheets may be accomplished either by cutting one or both of the two sheets to size before assembly. Alternatively, the assembly may be accomplished by placing weakening lines or cuts in a rectangular shape in the face layer of a continuous web, removing the face material around the rectangle of face material, and then cutting the web into similar sheets. To utilize this embodiment, the smaller rectangular sheet of face material may be removed from the second layer of material after printing and applied to a secondary surface. The adhesive may be continuous or discontinuous, as described above.
• In further embodiments, asheet108 of printing stock may be configured to work with ink jet printers that have the capability to print to the edge of the sheet. In embodiments in which a printer is able to print to three of the four edges of the sheet, thereby leaving one edge with a margin, the sheet may include a weakening line or face cut on one edge only. The construction may be a laminate or a single layer, with or without adhesive, and the weakening line may be continuous or discontinuous, with any of the variations described above. In embodiments in which a printer is able to print all the way to all four edges of the sheet, a laminate sheet with face material, adhesive, and release-coated liner with no weakening lines may be utilized. The adhesive may be incorporated as described above. Alternately, the sheet may have no adhesive, with the adhesive being supplied independently or applied to a carrier sheet.
• Yet other embodiments may incorporate one or more methods of attaching the sheets to a secondary surface or a carrier without the use of adhesive on the sheet or on the carrier. In these embodiments, a third element may be utilized that has adhesive covering some or all of a back side, and a clear face side. This third element may form a sleeve that is large enough for inserting the entire sheet into the sleeve. Alternatively, the third element may be smaller than the sheet and may capture one corner of the sheet only, in which embodiment four of these elements may be used per sheet. The third element may also capture the corners of more than one sheet, so that one corner of one to four of the sheets may be captured by each corner element. In other embodiments, the third element may include slots or grooves for capturing a respective edge of the sheet. Two to four of these elements may be used per sheet. These elements may be supplied either already attached to a carrier or separately. The elements may be designed to allow the sheets either to have butted edges or to overlap. The elements may allow for movement of the sheet within the element or may grasp the sheet by pressure between two opposing surfaces.
• According to further embodiments, asheet108 of printing stock may utilize static-cling sheets to bond to a secondary surface. Alternatively, thesheet108 may utilize magnetic sheets to bond to a secondary surface. In either embodiment, the sheets may have continuous weakening lines or discontinuous weakening lines, or may be free of weakening lines.
• In other embodiments, asheet108 of printing stock may include a single sheet that is approximately four times the size of a standard printable sheet, which has been folded once on center in one direction, and then once on center 90 degrees from the first fold, creating a folded sheet that is one-fourth the size of the original sheet. The sheet of this embodiment may be printed in folded form, first one side, then the other. Then the second fold may be reversed, and the other two quadrants may be printed, first one side, then the other. Finally, the sheet may be unfolded. The resulting total image is printed on one sheet, with no adhesive or secondary surface required.
• Those skilled in the art will understand that the preceding embodiments of the system provide the foundation for numerous alternatives and modifications thereto. For example, the printing stock may be used to print signs that fit on asingle sheet108 of printing stock. In addition, thelayer122 of adhesive may be applied in a pattern on theback side124 of theface sheet114 so that theadhesive surface120 is adherent substantially only at the portion thereof that is adjacent to theborder134 of thebacking sheet116. Further, rather than cutting into or through theface sheet114, the registration marks154 may be applied to theprinting surface118 by thecomputer104 during the printing of the sub-images112 thereon. These other modifications are also within the scope of the present invention. Accordingly, the present invention is not limited to that precisely as shown and described herein.

Claims (21)

1. (canceled)

2. The printing stock ofclaim 20, wherein the at least one registration mark is formed by discontinuities in the face cut.

3-4. (canceled)

5. The printing stock ofclaim 15, wherein at least one section of the backing cut extends spatially beyond the face cut, thereby forming at least one tab section that is juxtaposed over the margin of the face sheet, such that when the margin is removed from the face sheet, the at least one tab section extends beyond an edge of the face sub-sheet.

6-14. (canceled)

15. Printing stock for use in making a sign, the sign being formed by overlapping a plurality of sheets of the printing stock arranged in a pattern, the printing stock comprising:

a face sheet including:

a printing surface;

an adhesive surface; and

a face cut forming a margin and a face sub-sheet such that at least a portion of the margin is separable from the face sub-sheet; and

a backing sheet releasably coupled to the adhesive surface and including a backing cut forming a border and a backing sub-sheet such that at least a portion of the border is separable from the backing sub-sheet so that at least a portion of the adhesive surface of the face sheet is exposable.

16. The printing stock ofclaim 15, wherein the face sheet has a size selected from a group consisting of A4, 8½×11 inches, and legal size.

17. The printing stock ofclaim 15, wherein the printing stock is receivable through a small-office, home-office (SOHO) printer.

18. The printing stock ofclaim 15, wherein the face cut includes a die cut.

19. The printing stock ofclaim 15, wherein the backing sheet and the face sheet have a perimeter, the face cut being spatially positioned between the perimeter and the backing cut.

20. The printing stock ofclaim 15, wherein the face sheet further includes at least one registration mark that is configured to enable the face sub-sheet from one sheet of printing stock that is separated from at least a portion of the margin thereof to be positioned with respect to the face sub-sheet from another sheet of printing stock.

21-40. (canceled)

41. Printing stock for use in making a sign, the sign being formed from a plurality of sheets of the printing stock arranged in a pattern, the printing stock comprising:

a face sheet including:

a printing surface;

an adhesive surface; and

a face cut forming a margin and a face sub-sheet such that at least a portion of the margin is separable from the face sub-sheet; and

a backing sheet including:

a backing cut forming a border and a backing sub-sheet, at least one section of the backing cut extending spatially beyond the face cut, thereby forming at least one tab section that is juxtaposed over the margin of the face sheet, such that when the margin is removed from the face sheet, the at least one tab section extends beyond an edge of the face sub-sheet.

42. The printing stock ofclaim 41, wherein the face sheet has a size selected from a group consisting of A4, ½×11 inches, and legal size.

43. The printing stock ofclaim 41, wherein the printing stock is receivable through a small-office, home-office (SOHO) printer.

44. The printing stock ofclaim 15, wherein the backing sheet includes a release coating.

45. The printing stock ofclaim 41, wherein the backing sheet includes a release coating.

46. The printing stock ofclaim 41, wherein the face cut includes a die cut.

47. The printing stock ofclaim 41, wherein the face sheet further includes at least one registration mark that is configured to enable the face sub-sheet from one sheet of printing stock that is separated from at least a portion of the margin thereof to be positioned with respect to the face sub-sheet from another sheet of printing stock.

48. Printing stock for use in making a sign, the sign being formed by overlapping a plurality of sheets of the printing stock arranged in a pattern, the printing stock comprising:

a face sheet including:

a printing surface;

an adhesive surface; and

a face cut forming a margin and a face sub-sheet such that at least a portion of the margin is separable from the face sub-sheet; and

a backing sheet releasably coupled to the adhesive surface and including a backing cut;

wherein:

the backing cut forms a border and a backing sub-sheet such that at least a portion of the border is separable from the backing sub-sheet and that at least a portion of the adhesive surface of the face sheet is exposable; and

at least one section of the backing cut extends spatially beyond the face cut, thereby forming at least one tab section that is juxtaposed over the margin of the face sheet, such that when the margin is removed from the face sheet, the at least one tab section extends beyond an edge of the face sub-sheet.

49. The printing stock ofclaim 48, wherein the face sheet further includes at least one registration mark that is configured to enable the face sub-sheet from one sheet of printing stock that is separated from at least a portion of the margin thereof to be positioned with respect to the face sub-sheet from another sheet of printing stock.

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