Multi-Layer Cards with Aesthetic Features and Related Methods of Manufacturing

• US 20080245865A1
• Filed: 08/09/2004
• Published: 10/09/2008
• Est. Priority Date: 08/09/2004
• Status: Active Grant

• Current Assignee: IDEMIA France (Advent International Corporation)
• Original Assignee: IDEMIA France (Advent International Corporation)
• Inventors: Mosteller, Barry
• Granted Patent: US 8,061,618 B2
• Time in Patent Office: Days
• US Class Current: 235/449
• CPC Class Codes: B42D 2033/10 Metallic material
• CPC Class Codes: B42D 25/00 Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof printing processes to produce identification or security features B41M3/14
• CPC Class Codes: B42D 25/23 Identity cards
• CPC Class Codes: B42D 25/351 Translucent or partly translucent parts, e.g. windows
• CPC Class Codes: B42D 25/47 using adhesives

Abstract

Multi-layer cards with aesthetic and/or functional features, e.g. banking, access, or identification cards, having a bearing layer that includes an effects layer disposed directly between two core layers are disclosed herein. Among other potential benefits, the layered structure of the bearing layer reduces overall manufacturing costs, as compared to methods known in the art, by facilitating a balanced card construction while minimizing the number of layers formed from relatively expensive materials, avoiding direct imaging of the effects layer and minimizing waste associated therewith, as well as providing for reliable incorporation of the effects layer into the multi-layered structure with minimal expenditure of resources and reduced possibility of waste.

Claims

1. A multi-layer card that meets ASO/ISO specifications, the multi-layer card comprising a bearing layer, the bearing layer comprising:

(a) a first core layer, wherein the first core layer is transparent or translucent;

(b) a second core layer; and

(c) an effects layer disposed directly between the first core layer and the second core layer, wherein the effects layer comprises;

(i) a transparent or translucent substrate having a first surface; and

(ii) a first material deposited over the first surface.

3. The multi-layer card of claim 1, wherein the substrate comprises a polymer selected from the group consisting of polyethylene terephthalate and polycarbonate.

5. The multi-layer card of claim 1, wherein the first material is vacuum coated over the first surface of the substrate.

7. The multi-layer card of claim 1, wherein the first material comprises a metal selected from the group consisting of aluminum, copper, tin, and combinations thereof.

8. The multi-layer card of claim 1, wherein first material comprises a nonmetallic compound selected from the group consisting of metal oxides, metal nitrides, metal carbides, metal oxynitrides, metal oxyborides, and combinations thereof.

9. The multi-layer card of claim 1, wherein the effects layer comprises at least one holographic image.

10. The multi-layer card of claim 1, wherein the effects layer comprises a plurality of woven fibers comprising a second material.

12. The multi-layer of claim 10, wherein the second material comprises nylon coated with polyvinylchloride.

16. The multi-layer card of claim 1, wherein the bearing layer has a thickness of less than 10 mils.

17. The multi-layer card of claim 1, wherein the bearing layer has a thickness ranging from about 7 mils to about 9 mils.

18. The multi-layer card of claim 1, wherein the effects layer has a thickness ranging from about 1 mil to about 2 mils.

20. The multi-layer card of claim 1, wherein at least one of the first core layer and the second core layer comprises a polymer selected from the group consisting of polyester, glycolised polyester, and polyvinylchloride.

23. The multi-layer card of claim 1, further comprising an outer layer disposed over at least one of the first core layer and the second core layer.

24. The multi-layer card of claim 23, wherein the outer layer is substantially transparent.

25. The multi-layer card of claim 23, wherein the outer layer comprises a polymer selected from the group consisting of polyester, glycolised polyester, and polyvinylchloride.

26. The multi-layer card of claim 23, wherein the outer layer has a thickness of about 9 mils.

28. The multi-layer card of claim 23, further comprising a substantially transparent protective layer disposed at least over at least one of a graphic image, a numerical symbol, or a text symbol created on at least one surface of the outer layer.

29. The multi-layer card of claim 28, wherein the protective layer comprises polyvinylchloride.

31. The multi-layer card of claim 23 further comprising a magnetizable layer disposed over the outer layer.

32. The multi-layer card of claim 23, further comprising at least one integrated circuit embedded therein.

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