Abstract:
A hybrid plastic card, such as a radio frequency identification card, including at least one electronic element embedded therein and a hot lamination process for the manufacture of radio frequency cards and other cards including a micro chip embedded therein. This card has an application on the surface of security overlaminate and a laser photo optical memory strip with the CD-ROM disk technology. The process results in a card having an overall thickness in the range of 0.028 inches-0.033 inches with a surface suitable for receiving dye sublimation printing—the variation in card thickness across the surface is less than 0.0005 inches. A card manufactured in accordance with the present invention also complies with all industry standards and specifications. Also, the hot lamination process of the present invention results in an aesthetically pleasing card. The invention formed in accordance with a hot lamination process and the continuation of the present invention.

Description:
This application claims the benefit of U.S. Provisional Application Nos.: 
     
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 APPLICATION NO. 
                 FILING DATE 
               
               
                   
                   
               
             
             
               
                   
                 60/157,054 
                 10/01/1999 
               
               
                   
                 60/218,456 
                 07/14/2000 
               
               
                   
                   
               
             
          
         
       
     
    
    
     FIELD OF INVENTION 
     The present invention relates to combining a radio frequency card and a laser optical memory card that conforms to industry size and performance standards and conventions and that have a superior outer surface to known RFID cards such that card may receive dye sublimation printing and laser optical memory stripe. 
     BACKGROUND OF THE INVENTION 
     As the use of plastic cards for credit cards, automated teller machine (ATM) cards, identification cards, and like continues to become more widespread, the problems associated with the use of such cards correspondingly increase. Credit card fraud and identification card fraud are becoming larger problems everyday, and this fraud has introduced uncertainties into our systems of commerce and our security systems. Using easily available technology, criminals are able to manufacture credit/debit cards, ATM cards, identification cards, and the like having another&#39;s account code, identification code, or other personal information embedded in the magnetic stripe thereof. Thus, for example, criminals may steal hundreds or thousands of legitimate credit card account numbers and manufacture many additional cards bearing the stolen information. These fraudulent cards are then usable by the criminals to purchase goods and to receive cash with the legitimate card holder and the card issuer left holding the bill. Likewise, so called debit cards are becoming increasingly popular. These cards have stored thereon a certain amount of value for which the card owner has previously paid. For example, a subway rider may purchase a card good for 50 fares, with one fare being deducted from the card each time the owner rides the subway. Criminals have also been able to manipulate the data stored on these cards to defraud the merchants and others. 
     The ease in which criminals have been able to manufacture and or manipulate known cards results from the existence of the easily altered magnetic strip storage medium used by known cards. These magnetic stripes are easily programmed and reprogrammed using commonly available technology. Thus, there has been found a need in the plastic card industry to provide a more secure plastic card that is very difficult or impossible to fraudulently manipulate. The most likely solution to the above-noted problems associated with known plastic cards is the RFID card and other cards including computer chips embedded therein rather than, or in addition to, a magnetic stripe. While these RFID cards and like have been found to be successful in preventing or limiting fraud, they are more difficult and expensive to manufacture relative to ordinary magnetic stripe cards. One of the biggest obstacles to the wide spread manufacture and use of RFID cards has been the inability of card manufacturers to manufacture an RFID card that meets all industry standards and specifications, such as those set by the International Standards Organization (ISO), that are sufficiently aesthetically pleasing (wherein the embedded electronics are hidden from view), and that have a sufficiently regular or flat surface such that one or both surfaces of the card may be printed on using the very popular and widespread dye sublimation technology. Known plastic cards with computer chips and like embedded therein are too thick to work in connection with existing card reading machinery (ATM machines, telephones, and like) and have a surface that is too irregular to properly and consistently receive dye sublimation printing. Furthermore, prior attempts to manufacture a sufficiently thin plastic card including a computer chip embedded therein have results of a card with inferior aesthetic qualities such as the ability to see the embedded computer chip through the plastic. 
     SUMMARY OF THE INVENTION 
     There are several lamination methods in the plastic card industry, such as: 
     1. Hot and cold using a platen laminator with controlled hydraulic ram pressure. 
     2. Hot and cold roll laminators. 
     3. Lamination using adhesives cured by ultra violet radiation, electron beam radiation, or cold roll on contact adhesive. 
     SUMMARY OF THE INVENTION 
     This invention requires a combination of several lamination processes to manufacture a Hybrid/Contactless Smart and Laser Optical Card. 
     The present invention is therefore directed to a hot lamination method for the manufacture of plastic cards including an electronic computer chip therein. The hot lamination method comprises the steps of providing first and second plastic core sheets, positioning at least one or more electronic elements between the first and second core sheets to thus form a core, and placing the core in a laminator and closing the laminator without applying pressure to the substrates. A heat cycle is applied to the core sheets in the laminator, thus liquefying the sheets and the laminator ram pressure is then increased in combination with the heat. A cooling cycle is then applied to the core in the laminator, preferably with an associated increase in ram pressure, and the core is removed from the laminator. At least one or more surface of the core is then printed on using a printing press or similar printing apparatus to print the cutting marks on the substrate for the purpose of cutting the cards of the finished step and also permit the cutting of the sheets into strips containing one or more of the electronics. At this point of the process the sheets can then be overlaminated with an overlaminate film and placed in a laminator and complete the second lamination process, thus giving a smoothness of 0.0005 inches and a combined card thickness of between 0.028 inches to 0.033 inches. These sheets can then be cut into strips and the strips can be welded together via means of ultrasonic welding, chemical adhesive or hot melt glue, thus forming a continuous web to be used in the process of manufacturing an optical memory cards. This would complete a laminated card prepared for the application of an optical memory stripe. 
     The present invention provides numerous advantages over known card manufacturing processes, including the formation of a plastic card with electronic elements such as a computer chip embedded therein with a pleasing aesthetic appearance, with a sufficiently smooth and regular surface such as the card may receive a optical memory stripe and dye sublimation printing with sufficient durability and characteristics to comply with all industry specifications and standards. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a plastic card in accordance with the present invention; 
     FIG. 2 is a side elevational view of the card shown in FIG. 1; 
     FIGS. 3A-3E are top plan views of various electronic elements that may be embedded in a card in accordance with the present invention; 
     FIG. 4 is an exploded, schematic view of an electronic element position between two plastic core sheets to form a core; 
     FIG. 5 is a top plan view of a plurality of electronic elements positioned on a sheet of plastic core stock such that they may be covered by a similar sheet of core stock; 
     FIG. 6 is a schematic cross-sectional view of one or more electronic elements positioned between sheets of plastic core stock; 
     FIG. 7 schematically illustrates a book comprising the core, as it is positioned in a laminator apparatus; 
     FIG. 8 schematically illustrates the core as it is being printed on after removal from the laminator using a printing press or similar printing apparatus; 
     FIG. 9 is a cross sectional view schematically illustrating the application of printing marks for shear optically cutting and optically cutting the individualized cards. 
     FIG. 10 is a top view of the sheet illustrating hidden electronics within the sheet illustrating printed marks for cutting the sheet into strips and cutting the individual cards from the strips. 
     FIG. 11 is an illustration of a strip of hidden electronics in a strip cut from the sheet. 
     FIG. 12 is an illustration of trimmed strips welded or glued together to form a continuous strip of hidden electronics within the strip illustrating printed optical cutting marks or images. 
     FIG. 13 illustrates a roll of strips glued together to form a continuous web of electronics containing images and optical cut marks. This illustration is the completed web ready for the application of overlay and optical laser receptive strips to complete a hybrid radio frequency and laser optical memory card. 
     FIG. 14 is an illustration of a top view of a laser optical memory card containing hidden radio frequency electronics. 
     FIG.  15 . is an illustration of cross-section view of a laser optical memory card containing radio frequency electronics. 
     FIG.  16 . is an illustration applying overlaminate and laser optical memory strip to the continuous web 
     FIG.  17 . Illustrates a book comprising the core as it is positioned in the laminator apparatus. The core is illustrated containing a printing on one or more of the surfaces overlaid with overlaminate film on one or both sides of the surfaces of the core. This book is positioned between glossy laminating plates and the plates are positioned between laminating pads. The pads are positioned between laminating trays. The laminating trays are positioned between the platens of the laminator, thus completing the final lamination process to produce a glossy card with a completed card thickness of 0.028 inches to 0.033 inches with a surface smoothness of 0.0005 inches that may receive dye sublimation printing and also an optical memory strip with CD-ROM technology. 
     FIG.  18 . Illustrates a continuous roll of strips affixed together of overlaminated printed cards containing contactless integrated circuit chips and antennas, being overlayed with optical memory strip with CD-ROM technology and cut out from this continuous roll or form. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to a plastic card combining two different technologies (1) at least one electronic element embedded therein and (2) a laser optical memory strip layered on the surface of the card. The present invention also relates to a hot lamination process for the manufacture of plastic cards containing both of these elements and more particularly to a hot lamination process for the manufacture of plastic cards that include an electronic element, such as a computer chip or to the electronic element embedded therein. The electronic element may perform a wide variety of functions and take a wide variety of forms. Also, these cards will have a laser optical memory strip or CD-ROM disk applied to the surface. Such cards will hereinafter be referred to as a hybrid radio frequency identification card (RFID) and laser memory strip card or CD-ROM disk TECHNOLOGY. The present invention also relates to a card formed in accordance with the invention. 
     Referring now to FIG. 1, there can be seen a plastic RFID card  33  manufactured in accordance with the present invention and including a electronic element  20  embedded therein. 
     Card  33  includes an upper surface  34  and a lower surface  35  as illustrated in FIG.  2 . Electronic element  20  may take a wide variety of forms and perform a variety of functions as shown in FIG. 3A-3E respectively, electronic element  20 ,  20 ′,  20 ″,  20 ′″,  20 ″″ may be provided by a micro chip  22  including a wire antenna  24  connected thereto, a micro chip  22 ′ and circuit board antenna  24 ′, a read/write micro chip and  22 ″ and a wire coil antenna  24 ″, or any other suitable electronic element. These electronic elements  20 ,  20 ′,  20 ″,  20 ′″,  20 ″″ and other insertions into plastic cards is not new, however, the present invention provides a new hot lamination process for manufacturing plastic cards  33  with these electronic elements  20 ,  20 ′,  20 ″,  20 ′″,  20 ″″ embedded therein such that the cards  33  are of a superior quality. Specifically, a card in accordance with the present invention will have a variance in thickness depending on how many different applications will be added such as security, holographic overlaminate films and optical memory strips or CD-ROM disks. 
     As shown in FIG. 4-10 one or more cards  33  in accordance with the present invention may be manufactured by positioning an electronic element  20  between first and second sheets of card stock  34 ,  35  to form a core  33 . Preferably as shown in FIG. 5-10 a plurality of cards are manufactured simultaneously, in thus, a plurality of electronic elements  20  are positioned between the first and second sheets of plastic core stock  34 ,  35  (only the second sheet  35  being shown in FIG. 5 for clarity). When a plurality of electronic elements  20  are positioned between first and second sheets of plastic core stock  34 ,  35 , electronic elements  20  are properly positioned relative to one another such that a plurality of cards may be cut from the resulting card stock. Plastic core sheets  34 ,  35  may be provided by a wide variety of plastics, the preferred being polyvinyl chloride (PVC) having a thickness in the range of 0.006 inches and preferably having a combined thickness of approximately 0.0125 inches. Those skilled in the art will recognize that the thickness of the plastic core electronic elements that are to be embedded there between. Other suitable plastics that may be utilized include polyester, acrylonitrile-butadiene-styrene (ABS), polycarbonate and any other suitable plastic. 
     Subsequent to placing one or more electronic elements  20  between the first and second sheets  34 ,  35  of plastic core stock to form a core  33 , this core  33  is placed in a laminator apparatus  40  of the type well known in the art of plastic card manufacturing. As shown in FIG. 7, laminator  40  includes upper and lower platens  42 ,  44  for applying ram pressure to an article positioned there between. In addition to the ability to apply ram pressure, laminator  40  is preferably of the type having controlled platens  42 ,  44  that may provide both heat and chill cycles and preferably includes cycle timer to regulate cycle time. Core  33  is positioned between first and second laminating plates  50 ,  52 , one of which is preferably matte finished to provide laminated core  33  with at least one textured outer surface. First and second laminating pads  60 ,  62  are positioned outside of the laminating plates  50 ,  52  and first and second steel plates  70 ,  72  are likewise positioned outside of pads of  60 ,  62  and the entire assembly forms a book  35  for being positioned in laminator  40  between platens  42 ,  44 . 
     Once book  35  is positioned in laminator  40  as shown in FIG. 7, the first lamination cycle is initiated by closing laminator platens  42 ,  44 , preferably applying little or no ram pressure to book  35 . A laminator heat cycle is initiated, bringing the temperature of platens  42 ,  44  up to a range of 275° F. to 400° F., and most preferably up to a range of 300° F. to 370° F. for a period of greater than 5 minutes, and preferably in the range of 7 to 10 minutes. Once the heat cycle has been applied to the book  35  as is set forth above, the ram pressure of laminator  40  is increased to facilitate the flow of the plastic core sheets  34 ,  35  so that the one or more electronic elements  20  are encapsulated thereby, and so that sheets  34 ,  35  form a uniform core  33  (seen most clearly in FIGS. 8-10) with upper and lower surfaces  34 ,  35 . As mentioned, the use of matte finished laminator plates  50 ,  52  provides surfaces  34 ,  35  with a slightly roughened or textured quality which will facilitate the application of a coating thereto as is discussed below. The ram pressure applied during the heat cycle and the length of the heat cycle may vary, depending especially upon the size of sheets  34 ,  35 . For example, the cycle time may be in the range of 10-15 minutes. In one example, a ram pump pressure of 940 pounds per square inch (p.s.i.) was applied for 10-15 minutes to form a uniform core  33 , using sheets  34 ,  35  of a size in the range of 12 inches by 24 inches to 24 inches by 36 inches. 
     Subsequent to the above heat cycle, laminator  40  applies a chill cycle to book  35  during which time the ram pressure of the laminator  40  is increased, preferably by approximately 25% until the platens  42 ,  44  have cooled to approximately 40° F. to 65° F. for approximately 10-15 minutes. Core  33  may then be removed from laminator  40  for additional processing. 
     Subsequent to the removal of core  33  from laminator  40  and as illustrated in FIG. 8, core  33  is coated on at least one of it&#39;s upper and lower surfaces  34 ,  35  with a layer of printing ink  36 . This may be accomplished using a wide variety of printing techniques such as offset printing, letterpress printing, screen printing, roller coating, spray printing, litho-printing, and other suitable printing techniques. As shown in FIG. 8, core  33  is fed in the direction indicated with arrow A through a printing press, a lithographic printer, or a similar apparatus  80 . This printing step is performed to coat at least one surface  34 ,  35  of core  33  with a layer of aesthetically pleasing ink  36 . This layer of ink  36  cosmetically hides the one or more electronic elements  20  that are embedded within core  33 , and prevents these one or more electronic elements  20  from showing through the relatively thin core  33 . In this manner, the one or more electronic elements  20  encapsulated in core  33  are completely hidden from view without requiring the plastic used in the manufacture core  33  to be excessively thick. 
     Referring now to FIG. 9-10 the drawings illustrate layering of printing on surfaces  34  and  35 . As illustrated in FIG. 10 print marks  36  facilitates cutting the sheets into strips as illustrated in FIG.  11 . 
     FIG. 11 illustrates a strip cut from the sheet of  33  FIG.  10 . the strip illustrates optical trim marks  37 . When ends of the strips are trimmed cutting off the ends containing optical trim marks  36  the strip can then be affixed together via means of ultrasonic welding or gluing joining the strips together  38  as illustrated in FIG.  12 . 
     FIGS. 10,  11  and  12  illustrates sheets made into strips with optical cut marks. 
     FIG. 13 illustrates a roll  39  of continuous strips affixed together. This roll of continuous strips can then be applied as a substrate in the use of manufacturing laser optical memory cards as using CD-ROM disk technology. This would then produce a hybrid card using two extremely high noncounterfeitable technologies as illustrated in FIG.  14 . 
     FIG. 14 illustrates a top view of a single card containing a RFID contactless smart chip and electronics a laser photo optic memory strip  45  with CD-ROM disk technology. This card is then ready for encoding on the optical memory strip and writing into the smart chip  20  and receiving dye sublimation printing and encoding a magnetic strip if used. 
     FIG. 15 illustrates a side cross-section of a single card containing a “RFID contactless smart chip and a cross-section of the layering of ink  36  and security overlaminate and laser photo optical memory strip  45  with CD-ROM disk technology. FIG. 15 also illustrates overlaminate film  41 , layered over printing  36  of FIG.  9  and FIG.  10 . 
     FIG. 16 illustrates a roll of electronics embedded in a core stock  33  printed  36 - 37  and layered with security holographic overlaminate  41  via electron beam or ultra violet photo adhesive or cold contact glue  43  and layered with a roll strip of laser photo optical memory or CD-ROM disk technology  45 . FIG. 16 also illustrates the card  33  being cut from the continuous form of the hybrid cards as illustrated top view of FIG.  14 . 
     FIG. 17 illustrates  80  of FIG. 9 placed in laminator  40  layered between overlaminate film  41 .  41  layered between glossy laminating plates  81  and  82 . Laminating plates  81  and  82  are layered between laminating pads  60  and  62 . Pads  60  and  62  are layered between trays  70  and  72 . FIGS. 72,  62 ,  82 ,  41 ,  81 ,  60 , and  70  makeup a book  90 . Book  90  is placed between platens  44 ,  42  of laminator  40 . A normal laminating cycle of FIG. 17 is applied to book  90  with minimal ram pressure of the laminator  40 . At the start of the heat cycle approximately 50 pounds PSI increasing to 250 lbs. PSI of pressure through the heat cycle of 285° F.-300° F. At the start of the chill cycle the ram pressure is increased approximately 20% after the chill cycle is complete between 45° F.-65° F. the pressure is released and the book is removed from the laminator. 
     FIG. 18 illustrates a roll of laminated cards being overlayed with optical memory strip  45 , and cards being cut  46 , from a continuous substrate. FIG. 13 illustrates a roll  39  of continuous strips affixed together. This roll of continuous strips can then be applied as a substrate in the use of manufacturing laser optical memory cards as using CD-ROM disk technology. This would then produce a hybrid card using two extremely high noncounterfeitable technologies as illustrated in FIG.  14 . 
     FIG. 14 illustrates a top view of a single card containing a RFID contactless smart chip and electronics a laser photo optic memory strip  45  with CD-ROM disk technology. This card is then ready for encoding on the optical memory strip and writing into the smart chip  20  and receiving dye sublimation printing and encoding a magnetic strip if used. 
     FIG. 15 illustrates a side cross-section of a single card containing a RFID contactless smart chip and a cross-section of the layering of ink  36  and security overlaminate and laser photo optical memory strip  45  with CD-ROM disk technology. 
     FIG. 16 illustrates a roll of electronics embedded in a core stock  33  printed  36 - 37  and layered with security holographic overlaminate  41  via electron beam or ultra violet photo adhesive or cold contact glue  43  and layered with a roll strip of laser photo optical memory or CD-ROM disk technology  45 . FIG. 16 also illustrates the card  33  being cut from the continuous form of the hybrid cards as illustrated top view of FIG.  14 .