PLASTIC CARD AND METHOD FOR MAKING A PLASTIC CARD

• US 20090181215A1
• Filed: 01/15/2008
• Published: 07/16/2009
• Est. Priority Date: 01/15/2008
• Status: Abandoned Application

• Current Assignee: Innovatier, Inc.
• Original Assignee: Innovatier, Inc.
• Inventors: KEIM, LAWRENCE J., SINGLETON, ROBERT W.
• Application Number:
  US12/014,412
• Publication Number:
  US 20090181215A1
• Time in Patent Office: Days
• US Class Current: 428/161
• CPC Class Codes: B29C 2045/14532 injecting between two sheets
• CPC Class Codes: B29C 45/14467 Joining articles or parts of a single article B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence
• CPC Class Codes: B29K 2075/02 Polyureas
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2307/308 Heat stability dimensional stability B32B2307/734
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2425/00 Cards, e.g. identity cards, credit cards
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B42D 2033/24 : Reliefs or indentations
• CPC Class Codes: B42D 2033/32 : Other 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 25/45 : Associating two or more layers
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24636 : Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A plastic card, including a bottom overlay, a top overlay positioned above a top surface of the bottom overlay and a core layer positioned between the top surface of the bottom overlay and the top overlay. A method for manufacturing a plastic card, including loading a bottom overlay into an injection molding apparatus, loading a top overlay into the injection molding apparatus wherein the top overlay is positioned above a top surface of the bottom overlay and injecting a core layer between the bottom overlay and top overlay, wherein one or more protrusions are formed on the surface of the top overlay. The protrusions may be arranged in such a way as to form designs on the surface of the plastic card.

Claims

1. A plastic card, comprising:

a bottom overlay;

a top overlay positioned above a top surface of the bottom overlay, wherein the top overlay or bottom overlay may have one or more protrusions; and

a core layer positioned between the top surface of the bottom overlay and the top overlay.

2. The plastic card, as claimed in claim 1, wherein the top overlay and bottom overlay are comprised of one of polycarbonate, polyvinyl chloride (PVC), polyethylene terephtalate (PET), or polyethylene terephtalate glycol (PETG).

3. The plastic card, as claimed in claim 1, wherein the core layer is thermosetting polymeric material.

4. The plastic card, as claimed in claim 1, wherein the core layer is comprised of polyurea.

5. The plastic card, as claimed in claim 1, wherein a thickness of a first portion of the plastic card is greater than or less than a second portion of the plastic card.

6. The plastic card, as claimed in claim 1, wherein the top overlay and bottom overlay are comprised of fabric.

7. The plastic card, as claimed in claim 1, wherein the one or more protrusions can be arranged to form a design.

8. The plastic card, as claimed in claim 1, wherein the top overlay and bottom overlay are comprised of any material configured to prohibit the core layer from penetrating through the top overlay or bottom overlay.

9. A method for manufacturing a plastic card, comprising:

loading a bottom overlay into an injection molding apparatus;

loading a top overlay into the injection molding apparatus wherein the top overlay is positioned above a top surface of the bottom overlay; and

injecting a core layer between the bottom overlay and top overlay, wherein one or more protrusions may be formed on the surface of the bottom overlay or top overlay.

10. The method of claim 9, further comprising removing top overlay and bottom overlay having an injected core layer from the injection molding apparatus and cutting out the plastic card.

11. The method of claim 9, wherein the core layer is thermosetting polymeric material.

12. The method of claim 9, wherein the core layer is polyurea.

13. The method of claim 9, wherein the top overlay and bottom overlay are comprised of one of polycarbonate, polyvinyl chloride (PVC), polyethylene terephtalate (PET), or polyethylene terephtalate glycol (PETG).

14. The method of claim 9, wherein the one or more protrusions can be arranged to form a design.

15. The method of claim 9, wherein the top overlay and bottom overlay are comprised of fabric.

16. The method of claim 9, wherein the top overlay and bottom overlay are comprised of any material configured to prohibit the core layer from penetrating through the top overlay or bottom overlay.

17. The method of claim 9, wherein the core layer is injected at a temperature of at most 150°

F.

18. The method of claim 9, wherein the core layer is injected at a pressure of less than 2500 psi.

19. A plastic card, comprising:

a bottom overlay;

a top overlay positioned above a top surface of the bottom overlay; and

a core layer positioned between the top surface of the bottom overlay and the top overlay.

20. The plastic card, as claimed in claim 19, wherein the top overlay and bottom overlay are comprised of one of polycarbonate, polyvinyl chloride (PVC), polyethylene terephtalate (PET), or polyethylene terephtalate glycol (PETG).

21. The plastic card, as claimed in claim 19, wherein the core layer is thermosetting polymeric material.

22. The plastic card, as claimed in claim 19, wherein the core layer is comprised of polyurea.

23. The plastic card, as claimed in claim 19, wherein a thickness of a first portion of the plastic card is greater than or less than a second portion of the plastic card.

24. The plastic card, as claimed in claim 19, wherein the top overlay and bottom overlay are comprised of fabric.

25. The plastic card, as claimed in claim 19, wherein the top overlay and bottom overlay are comprised of any material configured to prohibit the core layer from penetrating through the top overlay or bottom overlay.

26. A method for manufacturing a plastic card, comprising:

loading a bottom overlay into an injection molding apparatus;

loading a top overlay into the injection molding apparatus wherein the top overlay is positioned above a top surface of the bottom overlay; and

injecting a core layer between the bottom overlay and top overlay.

27. The method of claim 26, further comprising removing top overlay and bottom overlay having an injected core layer from the injection molding apparatus and cutting out the plastic card.

28. The method of claim 26, wherein the core layer is thermosetting polymeric material.

29. The method of claim 26, wherein the core layer is polyurea.

30. The method of claim 26, wherein the top overlay and bottom overlay are comprised of one of polycarbonate, polyvinyl chloride (PVC), polyethylene terephtalate (PET), or polyethylene terephtalate glycol (PETG).

31. The method of claim 26, wherein the top overlay and bottom overlay are comprised of fabric.

32. The method of claim 26, wherein the top overlay and bottom overlay are comprised of any material configured to prohibit the core layer from penetrating through the top overlay or bottom overlay.

33. The method of claim 26, wherein the core layer is injected at a temperature of at most 150°

F.

34. The method of claim 26, wherein the core layer is injected at a pressure of less than 2500 psi.