Method for making laminated, paper cards

1. A method for making a laminated, paper card, comprising:

adhering a first, flat side of a calendared paper to a first, flat side of a cellulose fiber board stock using a biodegradable adhesive to create a first, flat sheet of material;

adhering a first, flat side of a calendared paper to a first, flat side of a cellulose fiber board stock using a biodegradable adhesive to create a second, flat sheet of material;

adhering a second, flat side of the cellulose fiber board stock of the first, flat sheet of material to a second, flat side of the cellulose fiber board stock of the second, flat sheet of material using a biodegradable adhesive to create a flat, card construct;

providing a print to a second, flat side of at least one of the calendared papers of the flat card construct;

subjecting the printed card construct to a heat and pressure treatment in a hydraulic press; and

punching from the treated, printed, card constructs one or more flat, laminated, paper cards;

wherein the heat and pressure treatment comprises subjecting the printed card construct to a temperature between approximately 230 degrees F. and approximately 240 degrees F. at a pressure of approximately 150 psi and then subjecting the printed card construct to a temperature between approximately 60 degrees F. and approximately 70 degrees F. at a pressure of approximately 300 psi.

2. The method as recited in claim 1 , wherein the one or more flat, laminated, paper cards have an overall thickness in a range between 20 Mils and 30 Mils.

3. The method as recited in claim 2 , wherein the calendared paper in both the first, flat sheet of material and the second, flat sheet of material has a thickness between 4 Mils and 6 Mils and the cellulose fiber board stock in both the first, flat sheet of material and the second, flat sheet of material has a thickness between 6 Mils and 9 Mils.

4. The method as recited in claim 3 , wherein the biodegradable adhesive comprises a water based emulsion adhesive.

5. The method as recited in claim 1 , wherein the biodegradable adhesive comprises a water based emulsion adhesive.

6. The method as recited in claim 1 , wherein the calendared paper in both the first, flat sheet of material and the second, flat sheet of material comprises a lithographic grade calendared paper.

7. The method as recited in claim 6 , comprising using an offset printing process to provide the print to a second, flat side of at least one of the calendared papers of the flat card construct.

8. The method as recited in claim 1 , comprising providing a UV coating to the second, flat side of the calendared papers of the flat card construct.

9. The method as recited in claim 1 , comprising providing a thermal laminate to the second, flat side of the calendared papers of the flat card construct.

10. The method as recited in claim 9 , wherein the thermal laminate is provided to the second, flat side of the calendared papers by feeding the flat card construct into a roller machine having heated rollers between two layers of cellulose over laminate.

11. A method for making a laminated, paper card, comprising:

adhering a first, flat side of a calendared paper to a first, flat side of a cellulose fiber board stock using a biodegradable adhesive to create a first, flat sheet of material;

adhering a first, flat side of a calendared paper to a first, flat side of a cellulose fiber board stock using a biodegradable adhesive to create a second, flat sheet of material;

adhering a second, flat side of the cellulose fiber board stock of the first, flat sheet of material to a second, flat side of the cellulose fiber board stock of the second, flat sheet of material using a biodegradable adhesive to create a flat, card construct;

providing a print to a second, flat side of at least one of the calendared papers of the flat card construct;

subjecting the printed card construct to a simultaneously applied heat and pressure treatment followed by a simultaneously applied cooling and pressure treatment; and

punching from the treated, printed, card constructs one or more flat, laminated, paper cards.

12. The method as recited in claim 11 , wherein the one or more flat, laminated, paper cards have an overall thickness in a range between 20 Mils and 30 Mils.

13. The method as recited in claim 11 , wherein the calendared paper in both the first, flat sheet of material and the second, flat sheet of material has a thickness between 4 Mils and 6 Mils and the cellulose fiber board stock in both the first, flat sheet of material and the second, flat sheet of material has a thickness between 6 Mils and 9 Mils.

14. The method as recited in claim 11 , wherein the biodegradable adhesive comprises a water based emulsion adhesive.

15. The method as recited in claim 11 , wherein the calendared paper in both the first, flat sheet of material and the second, flat sheet of material comprises a lithographic grade calendared paper.

16. The method as recited in claim 11 , comprising providing a UV coating to the second, flat side of the calendared papers of the flat card construct.

17. The method as recited in claim 11 , comprising providing a thermal laminate to the second, flat side of the calendared papers of the flat card construct.

18. The method as recited in claim 17 , wherein the thermal laminate is provided to the second, flat side of the calendared papers by feeding the flat card construct into a roller machine having heated rollers between two layers of cellulose over laminate.

19. The method as recited in claim 11 , wherein pressure applied during the simultaneously applied cooling and pressure treatment is larger than pressure applied during the simultaneously applied heating and pressure treatment.