Abstract:
Composite cards formed in accordance with the invention include a security layer comprising a hologram or diffraction grating formed at, or in, the center, or core layer, of the card. The hologram may be formed by embossing a designated area of the core layer with a diffraction pattern and depositing a thin layer of metal on the embossed layer. Additional layers may be selectively and symmetrically attached to the top and bottom surfaces of the core layer. A laser may be used to remove selected portions of the metal formed on the embossed layer, at selected stages of forming the card, to impart a selected pattern or information to the holographic region. The cards may be ‘lasered’ when the cards being processed are attached to, and part of, a large sheet of material, whereby the “lasering” of all the cards on the sheet can be done at the same time and relatively inexpensively. Alternatively, each card may be individually “lasered” to produce desired alpha numeric information, bar codes information or a graphic image, after the sheets are die-cut into cards.

Description:
[0001]    This application is a continuation application of my co-pending application Ser. No. 12/006,168 filed Dec. 31, 2007 and titled Foil Composite Card, the contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention is directed to the manufacture of a multi-layered (composite) card, or any like instrument or document. 
         [0003]    The term “card” or “cards” as used herein, and in the appended claims, is intended to include a large variety of documents and instruments such as a financial cards, identification (including a National ID or Driver&#39;s License) cards, electronic passport pages, gift cards, documents for holding permanent and long lasting records such as medical records or security cards, or other plastic cards used for promotion of a product or organization. 
         [0004]    Various means of producing an improved composite card are disclosed in U.S. Pat. No. 6,644,552, titled Composite Card and issued to John Herslow, the applicant of this application, the teachings of which are incorporated herein by reference. However, there remains a demand for increasing the security of the cards (documents and/or instruments) being formed and used. For example, FIG. 4 of the &#39;552 Patent, shows security elements formed in a top layer  17  and FIG. 6 of the &#39;552 Patent discusses the addition of holographic material and other security indicia after the sheets are cut into standard cards. 
         [0005]    Thus, to increase the security of a card, it is known to form holograms on the card. Generally, the holograms may be formed by a hot stamping method at, or near, the top (or bottom) surface (level) of the card. A disadvantage to so placing the holograms is that a counterfeiter may be able to alter the card without the tampering being readily apparent to someone examining or accepting the card. Also, positioning the hologram close to the top or the bottom surface of the card creates an asymmetry in its construction, whereby, when the temperature varies, different portions (layers) of the card may be placed under different degrees of tension and contraction resulting in stresses which tend to distort the card and/or the hologram (e.g., the card fails to remain flat). Still further, when the hologram is placed at, or near, the top or the bottom surfaces it may be easily and inadvertently scratched or marred. 
         [0006]    Due to the highly sensitive nature of the “secure” cards, of interest, it is critical that they be made tamper resistant and sturdy and to last for a long time (e.g., more than 5 years) even where high temperature levels (hot or cold) and a high degree of humidity are encountered. It is also desirable that they be relatively inexpensive to fabricate and, very importantly, that the card be virtually impossible to be altered without destroying the card or the easy detection of the alteration. 
       SUMMARY OF THE INVENTION 
       [0007]    Accordingly, composite cards formed in accordance with the invention include a security layer formed at the center, or core layer, of the cards. Cards embodying the invention may include a hologram, or diffraction grating formed at, or in, the center, or core layer, of the card with symmetrical layers formed above and below the center or core layer. 
         [0008]    A hologram may be formed by embossing a designated area of the core layer with a diffraction pattern and vapor depositing a very thin layer of metal or metal compound (e.g., aluminum, zinc sulfide, etc . . . ) on the embossed layer. Then, additional layers are selectively attached to the top and bottom surfaces of the core layer. In accordance with the invention, for each additional layer attached to the top surface of the core layer there is a corresponding like layer attached to the bottom surface of the core layer for producing a highly symmetrical structure (sandwich). 
         [0009]    In accordance with one embodiment of the invention, all the layers are made of a clear synthetic (e.g., plastic) material, whereby the pattern formed on, or within, the core layer may be seen by looking down at the top of the card or by looking up at the bottom of the card. 
         [0010]    The layer of metal or metal compound deposited on the core layer may be made very thin to provide a “see-through” effect, under appropriate light conditions. However, where the layer of metal or metal compound deposited on the core layer is of “standard” thickness, the pattern may only be seen from the top or the bottom side of the core. 
         [0011]    After the hologram is formed, a laser may be used to remove selected portions of the metal formed on the embossed layer to impart a selected pattern or information to the holographic region. In accordance with the invention, this step in making a card or a set of cards may be performed when the card or cards being processed are attached to, and part of, a large sheet of material, whereby the “lasering” of all the cards on the sheet can be done at the same time and relatively inexpensively. 
         [0012]    In accordance with the invention a hologram may be formed in the core portion of card and if the hologram includes a metal layer, laser equipment may be used to modify and/or alter the metal pattern at selected stages in the process of forming the card. Alternatively, after the sheets are die-cut into cards, each card may be individually “lasered” to produce desired alpha numeric information, bar codes information or a graphic image. 
         [0013]    Embodiments of the invention may include the use of a polyester film, or any other carrier, which includes a metallic or a high refractive index (HRI) transparent holographic foil that is pre-laminated between two sheets of a material (which could be PVC, PET or other thermo-plastic resin) that has a thermo-plastic adhesive (which may have, but not necessarily has, been previously applied). The pre-laminated holographic foil can have an unlimited number of patterns and may also be configured to include one, or several individual, hologram designs repeated in rows and columns across an entire sheet. The holographic design may also have the appearance of full metal, or partial metal and partial white coverage (white reflecting hologram) on each individual card in the matrix. Utilizing this holographic foil pre-laminate in concert with standard plastic card materials, enables a plastic card manufacturer to produce “full-face” foil pattern design cards, or “full-face” registered hologram cards. 
         [0014]    These cards would include the holographic foil pre-laminate as the center sheet in a standard card composition. Utilizing the center sheet composition with a metal layer, the subsequent plastic card could be laser engraved using a standard YAG laser or any other suitable laser, thus removing the metal or material coatings of the holographic layer in one or more of the following: an alpha numeric, barcode or graphic design. The end result is an inexpensive foil composite card that has a unique individualized holographic layer that has been permanently altered. 
         [0015]    If a potential counterfeiter attempted to disassemble the card in order to compromise the integrity of the information contained on, or in, the card, it would cause a change in the hologram resulting in the hologram being irreparably damaged. Therefore, plastic cards formed in accordance with the invention are truly tamper resistant and are more secure foil cards than any of the known commercially available cards. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    In the accompanying drawings (which are not drawn to scale) like reference characters denote like components, and: 
           [0017]      FIG. 1  is a cross sectional diagram of part of a card (instrument) embodying the invention; 
           [0018]      FIG. 2  is a diagram detailing some of the steps in forming a card embodying the invention; 
           [0019]      FIG. 2A  is a diagram detailing the application of an embossing layer to a core layer to form a card embodying the invention; 
           [0020]      FIG. 3  is a cross sectional diagram of part of a card embodying the invention where the core layer includes a transparent material having a high refractive index; 
           [0021]      FIGS. 3   a ,  3   b ,  3   c ,  3   d , are cross sectional diagrams of steps in forming a card embodying the invention; 
           [0022]      FIG. 4  is a diagram of the cross section of part of a card embodying the invention to which a laser beam is applied to form an additional ablated pattern in a metal layer in accordance with the invention; 
           [0023]      FIG. 5  is a diagram of a top view of a card including a holographic portion formed in accordance with the invention; 
           [0024]      FIG. 6  is a cross sectional diagram of a card shown in  FIG. 5  where all layers are made of clear (transparent) materials; 
           [0025]      FIG. 6A  is a cross sectional diagram of a card embodying the invention where one, or more, of the layers block the light; 
           [0026]      FIG. 7  is a top view of a sheet containing an array of cards illustrating that a laser beam can be applied to all of the cards on the sheet; 
           [0027]      FIG. 8  is a cross sectional diagram of a card with an integrated circuit (IC) chip and antenna embodying the invention; 
           [0028]      FIG. 9  is a cross sectional diagram of a dual interface card embodying the invention; 
           [0029]      FIG. 10  is a cross sectional diagram of a card with a lasered window embodying the invention; 
           [0030]      FIG. 11  is a cross sectional diagram of another card with a lasered window embodying the invention; and 
           [0031]      FIG. 12  is a cross sectional diagram of still another card with a lasered window embodying the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]    Referring to  FIGS. 1 ,  2  and  2 A, there is shown a core  20  comprised of a base layer  21  of a plastic material, which may be, for example, oriented polyester terephthalate (OPET) or polypropylene, or polystyrene, or any number of acrylics and/or a combination of these materials. The base layer  21  is shown to have an upper surface  21   a  and a lower, or bottom, surface  21   b.  For purpose of illustration, a pattern is shown to be formed on, or above, surface  21   a  of layer  21 . However it should be understood that, alternatively, the pattern could be formed on surface  21   b.  Two different methods of forming a pattern are shown in  FIGS. 2 and 2A . The surface  21   a  of layer  21  in  FIG. 2  is embossed with a diffractive or holographic pattern. In  FIG. 2A , the surface  21   a  of layer  21  is coated with an embossing layer  200  which is then embossed with a diffractive pattern,  200   a.    
         [0033]    A layer  22  of aluminum (or any suitable metal or metal compound such as Zinc Sulfide) may then be vapor deposited on the diffraction pattern to form a hologram. The use of vapor deposition is very significant in that it permits a very thin layer  22 , a few atoms thick, to be formed on surface  21   a  and thus complete the formation of the hologram, using small amounts of metal. Using vapor deposition, the thickness of the layer can be made very thin so it is nearly transparent and can provide a “see-through” effect. Alternatively, the metal layer can be made a little thicker so as to be more opaque. 
         [0034]    As detailed in step  3  of  FIG. 2 , a clear adhesive primer layer  23   a,  may be coated over the patterned and metallized top surface ( 21   a ) and a similar clear adhesive primer layer  23   b  may be coated over the bottom surface ( 21   b ) of the layer  21 . The core  20  is completed by attaching these clear adhering layer ( 23   a,    23   b ) above and below the embossed base layer  21 . The clear layer  23   a,    23   b,  is a primer coating. It may be polyethylenamine or an acrylic based, or other, organic adhesive compound with solvent or water based carriers. The primer coatings  23   a,    23   b  are fairly thin and yet fairly strong/sturdy. They also function to promote adhesion to layers  24   a,    24   b  which are attached to the core  20 . 
         [0035]    As detailed in step  4  of  FIG. 2  clear PE adhesive layers  24   a,    24   b  may then be formed/attached to the top (outer) surfaces of their respectively layers  23   a,    23   b.  Layers  24   a,    24   b  may be of polyethylene (PE) material, or polypropylene (PP), or high density polypropylene (HDPP), or ethylene Vinyl Acetate (EVA), or any of the different forms of PET or any of like materials, or mixtures of these materials. The clear materials used to form layers  24   a,    24   b  may contain other clear adhesion promoting compounds (e.g., ethyl acrylates, acrylic acid, etc . . . ). The layers  24   a,    24   b  may be fairly thick and function to attach to the thin embossed hologram layer and coatings of core  20 . For handling purposes, buffer layers  25   a,    25   b  may then be formed/attached to the top (outer) surfaces of layers  24   a,    24   b  to complete what is defined as subassembly  30 . For example, buffer (carrier) layer ( 25   a,    25   b ) may be laminated to the top and bottom of adhesive layers  24   a,    24   b.  Subassembly  30 , is thick enough to be handled by automatic credit card manufacturing equipment. 
         [0036]    In one embodiment, the base layer  21  was approximately 0.002 inches thick and the adhesive backed layers ( 23   a,    23   b ) were each made to be approximately 0.0001 to 0.0003 inches thick. In other embodiments the layers  23   a,    23   b  could be made either thinner or much thicker. 
         [0037]    In still other embodiments, adhesive layers can be coated over the buffer or carrier layer and the two (i.e., the carrier and buffer layers on each side of a holographic layer) can be combined with the holographic layer. That is, adhesive can be applied to either side of the carrier foil interface and then pre-laminated together (3 sheets laminated to become one laminate; i.e., the prelaminate prior to platen lamination. Thus, the carrier sheet can hold the sub-assemblies for transfer to substrates for forming cards. 
         [0038]    Examining  FIG. 2  in greater detail note some of the steps used in forming the core  20 . 
         [0039]    As shown, for example, in step  1 , the base component may be a sheet  21  of plastic (e.g., PET or OPET or polypropylene, or polystyrene, or polymethyl, methacrylate, etc . . . ) material whose thickness typically ranges from 0.0005 inches to more than 0.005 inches. In one embodiment layer  21  was made, for example, 0.002 inches thick. 
         [0040]    Then, as shown in step  2 A, which may be termed an embossing step, a diffraction pattern may be formed on one side of layer  21 . A diffraction pattern may be formed directly in the plastic layer  21  by embossing (e.g., stamping) pattern(s) therein. Forming the pattern in a sheet of plastic (or in an embossing layer, as discussed below) is easier and less wearing on the embossing (stamping) equipment than forming a like pattern in a metal layer. 
         [0041]    Then, as shown in step  2 B a hologram is formed on one surface ( 21   a ) of plastic sheet  21  by vapor deposition of a metal layer (e.g., aluminum onto the diffraction pattern. Thus, the hologram may be formed by embossing the top surface  21   a  to form a diffraction pattern and then metallizing the pattern. The surface  21   a  may be coated by the vapor deposition of aluminum (or similar light reflective materials such as nickel, silver, zinc, or other like materials). A significant advantage of using vapor deposition (although many other methods may be used) is that very small amounts of the metal (light reflective material) need to be used to form the hologram resulting in a significant savings in the cost of manufacturing the card (or instrument). Also, very thin layers allow a controllable amount of light to pass through. This enables the manufacture of a card, or document, in which an image (hologram) formed on a card is reflected (i.e., is visible) while also enabling a viewer to “see-through” the image. 
         [0042]    Then, as shown in step  3  of  FIG. 2 , clear adhesive or “primer” coats  23   a,    23   b  may be applied to the top and bottom surfaces  21   a,    21   b,  respectively, of plastic sheet  21 . The primer coat also functions to fill in the ridges resulting from the formation of the diffraction grating. The clear layers  23   a,    23   b  which may be of the type described above, may be attached to the top and bottom surfaces of “embossed” plastic sheet  21  on which the aluminum has been vapor deposited. Primer layers  23   a,    23   b  may be attached to base layer  21  by any one of a number of methods, such as, for example, gravure coating, roller coating, flexography or other like methods. The primer secures the bond to both sides of the holographic sheet (the embossed side and the blank side). This completes the formation of what is defined herein as the core assembly  20 . 
         [0043]    Then, as shown in step  4  of  FIG. 2 , the PE layers  24   a,    24   b,  or any other suitable layer, as noted above, which function as an additional buffer between that bond and the outer buffer layers  25   a,    25   b  are attached to the core assembly. The PE layers  24   a,    24   b  may also include an adhesive which promotes adhesion to the clear primer layers  23   a,    23   b  attached to the top and bottom surfaces of layer  21 . Layers  24   a,    24   b,    25   a,    25   b  may be attached to each other and to the underlying layers by any one of a number of methods such as, for example, platen lamination, hot roll lamination, liquid adhesive lamination. 
         [0044]    Thus, as shown in step  4  of  FIG. 2 , a clear buffer layer  25   a  is attached to the PE layer  24   a  and a clear buffer layer  25   b  is attached to the PE adhesive layer  24   b.  All of layers  24   a  and  24   b  and layers  25   a,    25   b  function as buffers, providing additional strength to the structure and at the same time protecting the hologram from being damaged or tampered with. Adding layers  25   a  and  25   b  completes the sub-assembly  30  which may then be customized to form cards with additional information. 
         [0045]    By forming the hologram at, and within, the core level, the hologram will not be easily, or inadvertently, damaged since several additional layers will be attached to the top and bottom of the holographic layer. It is also not subject to easily being tampered or altered. Forming the hologram at the center of the structure minimizes the possibility of tampering while fully protecting the hologram. Another significant advantage of forming the hologram at the core of the structure is that the top and bottom surfaces stay flat due to equal shrinking and/or expansion of all the layers. Note that the card structure is formed so as to be symmetrical about the core layer. 
         [0046]      FIG. 2A  illustrates another method of forming the hologram. As shown in Step  1 A of  FIG. 2A , a clear embossing layer  200  may be coated directly over a layer  21  (or  210 ). Alternatively, a primer coating may be formed on layer  21 / 210  and then the embossing layer  200  may attached/formed to the primer coating. The embossing layer may be composed, for example, of siloxane, acrylic, vinyl, linear polyester, urethane or any like materials and may be several (e.g., less than 0.5 to more than 5) microns thick. The embossing layers may also be deposited as liquids and radiation cured, possibly in two steps—first as a soft easily embossable coating which then becomes hard and impervious. As shown in step  2 A of  FIG. 2A , a diffraction pattern is embossed (formed) in the embossing layer/coating  200  to form a desired pattern. Forming a pattern in the embossing layer may be desirable since it is even easier and less wearing on the embossing (stamping) equipment than forming a like pattern directly in the PET layer (as per  FIG. 2 ). After the pattern is embossed on and within the embossing layer  200 , the sheet may be processed as per steps  2 B,  3  and  4  shown in  FIG. 2 . 
         [0047]    [Note that a hologram may be formed by, for example, embossing a pattern in a carrier base material (e.g., a hard polyester) or by embossing the pattern in a coating previously applied to the carrier base material, or by embossing the pattern in a metal which was previously deposited onto the base carrier material or by depositing the metal onto a soft coating and then embossing.] 
         [0048]    Referring back to  FIG. 1 , note that the core  20  may be part of a subassembly  30  which includes attaching layers  24   a,    24   b  of clear PE and buffer layers  25   a,    25   b  to the top and bottom surfaces of the core  20 . Layers  25   a,    25   b,  may range in thickness from 0.001 to 0.005 inches, or more, and may be composed of PVC like materials. 
         [0049]    The subassembly  30  may then be used to form a card, or any instrument, by attaching a layer  27   a,    27   b  of clear or white PVC material to the top and bottom surfaces of the subassembly  30 . As illustrated in  FIG. 1 , information can be printed either on the outer surface (the surface facing away form the core) of layers  27   a,    27   b  or on the inner surface or both. The printed information may include, for example, fixed data fields and advertising, and/or any other desired information. The card (or instrument) may be completed by adding clear PVC laminating films  29   a,    29   b  to the top and bottom surfaces of the card. 
         [0050]      FIG. 3  is a cross-sectional diagram (not to scale) of a card embodying the invention.  FIG. 3  includes a core comprised of a layer  210  which may be (but not be) of the same material as layer  21 . In  FIG. 3 , the top surface  210   a  of layer  210  is embossed with a diffraction pattern giving a unique pattern to the structure. A high refractive index (HRI) layer  212  can then be vapor deposited on the embossed layer. Due to the HRI property of layer  212 , there is no need to further metallize the layer. The HRI layer may be formed of zinc sulfide or zinc oxide or any material having like properties. Clear primer layer  23   a  is attached to the top of HRI layer  212  overlying layer  210  and primer layer  23   b  is attached to the bottom of layer  210 . 
         [0051]    Then, as shown in  FIG. 1 , clear layers  24   a  and  24   b,  which may be of PE or any other suitable materials, are attached to layers  23   a  and  23   b,  respectively and additional layers ( 25   a,    25   b ) of clear (translucent) material may be attached to the top and bottom layers of layers  24   a,    24   b  to form the subassembly  30 . Additional layers  27   a,    27   b  may be attached to the top and bottom layers of the sub-assembly. Information may be written or printed in any known manner on, or in, the layers  27   a,    27   b.  Subsequently, laminating films  29   a,    29   b,  may be attached to the top and bottom intermediate layers  27   a,    27   b  to produce a card  40  whose core contents can not be altered without essentially destroying the card. 
         [0052]      FIGS. 3A ,  3 B,  3 C,  3 D and  3 E illustrate the forming/coating of an embossing layer  200  on stock (e.g., PET) material  210  ( FIG. 3A ), then embossing layer  200  with a diffraction pattern  200   a  ( FIG. 3B ), then vapor depositing an HRI layer  212   a  on the diffraction pattern ( FIG. 3C ), then coating clear primer layers  23   a,    23   b  above layer  212   a  and below layer  210  ( FIG. 3D ) to form a core assembly  20 . Then clear PE adhesive layer  24   a  is formed above prime layer  23   a  and clear PE adhesive layer  24   b,  is formed below layer  23   b  ( FIG. 3E ). Note that the steps and thicknesses of the layers to form the basic structures discussed above are summarized in Table I, below. 
         [0053]      FIG. 4  includes a cross-sectional diagram (not to scale) of a portion of a card embodying the invention, which may be part of a sheet (not shown) on which a large number of cards are formed, and depicts a piece of laser equipment  410  for “lasering” (e.g., engraving or vaporizing) metal layer  22 . The core assembly  20  is shown to have a layer  22  of aluminum deposited and embossed as discussed for  FIGS. 1 ,  2 , and  2 A, above. Portions of the metal layer may be vaporized (see sections  401   a,    401   b,    401   c ) by the laser equipment  410  such that portions of the metal are selectively removed or “ablated” by “lasering” (e.g., eliminating or vaporizing) the metal to form any number of different patterns (e.g., graphic as well as alpha numeric information may be generated). The clear layers  29   a,    27   a,    25   a  and  24   a  may be selected to be transparent to the laser wavelength. Consequently, the laser beam can pass through the clear layers of the card to “write” on the holographic layer below the top surface of the card. The laser  410  may be applied at several different stages of the card manufacturing process to form the desired patterns. Thus, the laser may be applied to “write” on the metal layer after the core  20  is formed and before the attachment of the carrier layers  24   a,    24   b  and  25   a,    25   b.  Alternatively, the laser  410  may be applied to form the desired pattern in the metal layer after the layers  24   a,    24   b,  and  25   a,    25   b  are attached to the core layer, and before layers  27   a  and  27   b  are attached. Still further, the laser may be applied to form the desired pattern in the metal layer after the layers  27   a,    27   b  are attached and before the layer  29   a,    29   b,  are attached. Finally, the laser may be applied to form the desired pattern in the metal layer after the layers  29   a,    29   b  are attached, when the cards may be part of a full sheet or in individual card shape. 
         [0054]      FIG. 5  shows a top view of a card  100  illustrating that the hologram may be ted within a designated window or area  101 , shown in portion  601 . Alternatively the hologram may extend the full length and/or width of the card  100 . Note that alpha numeric information may be produced by lasering within the holographic layer (e.g., layer  22  in  FIG. 4  shown in portion  602 ). Also, alpha numeric information may be produced by printing information on, or within, layers  27   a,    27   b,  as discussed above. 
         [0055]      FIG. 6  is a cross-sectional diagram (not to scale) of card  100  of  FIG. 5  and is intended to show that the layers above and below the holographic layer,  21 ,  22 / 212 , may be transparent or translucent to yield a “see-through” card with the hologram portion  601  and the lasered portion  602  being visible from the top side or from the bottom side of the card. Note that if layers  27   a,    27   b  are made of a white material a bright light may be needed to observe the “see-through” effect. 
         [0056]      FIG. 6A  is a cross-sectional diagram (not to scale) intended to show that the layers above the holographic layer  21 ,  22 / 212 , may be transparent or translucent so the holographic pattern may be seen from the top. At the same time, one or more of the layers below the holographic layer (e.g.,  27   b  or  29   b ) may be opaque so as to block the hologram from being seen from the bottom. Making the top portion of the card transparent and the bottom portion opaque is by way of illustration and the reverse could be done instead. 
         [0057]      FIG. 7  shows the application of a laser beam generated by laser equipment  410  to a sheet  5  containing a large array of cards  100  in sheet form embodying the invention. The laser may be applied to the entire sheet of cards which may be at the core stage, the sub-assembly stage, or any of the stages thereafter. Being able to apply the laser beam in this manner, at any time before the cards are separated from a sheet, is economically advantageous and saves much in the cost of handling and also adds significant additional security. 
         [0058]      FIG. 8  illustrates that cards embodying the invention, shown in the various figures, may be modified by the addition of a semiconductor chip containing selected electronic circuits (an integrated circuit, IC) within the body of the card in, or within, a layer  30  dedicated to include an antenna carrier, with the antenna being connected to the chip module. This enables the manufacture of a radio frequency identification (RFID) card. Note that the metal layer  22 / 212  can act as a radio frequency shield to reduce reception from that side of the RFID antenna. 
         [0059]      FIG. 9  illustrates that the chip (IC) and an antenna and carrier may be formed within a layer of the card and that, in addition, the chip may be accessed (read) by providing an external contact  901  along one side of the card. This type of card may be referred to as a dual interface card since it enables information on the card to be read or written via RFID and contact. 
         [0060]      FIG. 10  illustrates that a window or opening can be formed by lasering through the metal layer within core layer  20  to enable the color or pattern of an underlying layer (e.g.,  27   b ) to be seen from the top side of the card. Lasering through the metal layer forms (or opens) a window exposing an underlying layer (e.g.,  27   b ) which may be black or white or colored or be of any preset pattern. 
         [0061]      FIG. 11  illustrates that a window or opening can be formed by lasering the metal layer within core layer  20  to enable a preprinted image formed on an underlying layer (e.g.,  27   b ) to be seen from the top side of the card. Here again lasering through the metal layer forms a window enabling the seeing or reading of a pre-printed pattern on an underlying layer (e.g.,  27   b ). 
         [0062]      FIG. 12  illustrates that a window or opening can be formed by lasering through the metal layer within core layer  20  to provide a “see-through” condition. That is, lasering through the metal layer forms a window which provides visibility through both sides (top and bottom) of the card. This may be viewed by applying a light source such as a flashlight in direct contact with one side of the card and viewing the light pattern on the other side. 
         [0000]    
       
         
               
             
               
               
               
               
               
             
           
               
                 TABLE I 
               
             
             
               
                   
               
               
                 Example of Steps and materials in forming core, sub assembly and card 
               
             
          
           
               
                 step 
                 I 
                 II 
                 III 
                 IV 
               
               
                   
               
               
                 1 
                 Start with 
                 Start with 
                 Start with 
                 Start with base/central 
               
               
                   
                 base/central layer 
                 base/central 
                 base/central 
                 layer 21/210 
               
               
                   
                 21 of PET/OPET 
                 layer 21/210 
                 layer 21 of 
                 of PET/OPET material 
               
               
                   
                 material 
                 of PET/OPET 
                 PET/OPET 
               
               
                   
                   
                 material 
                 material 
               
               
                 1A 
                   
                 Deposit 
                   
                 Deposit embossing layer 
               
               
                   
                   
                 embossing 
                   
                 200 on one surface of 
               
               
                   
                   
                 layer 200 on 
                   
                 layer 21/210 
               
               
                   
                   
                 one surface of 
               
               
                   
                   
                 layer 21/210 
               
               
                 2 
                 Emboss one surface 
                 Emboss top 
                 Emboss one 
                 Emboss top surface of 
               
               
                   
                 of base layer 21 with 
                 surface of 
                 surface of base 
                 embossing layer 200 
               
               
                   
                 pattern 
                 embossing 
                 layer 21 with 
                 with pattern 200a 
               
               
                   
                   
                 layer 200 with 
                 pattern 
               
               
                   
                   
                 pattern 200a 
               
               
                 3 
                 Vapor deposition of 
                 Vapor 
                 Vapor 
                 Vapor deposition of HRI 
               
               
                   
                 metal 22 on pattern 
                 deposition of 
                 deposition of 
                 coating 212 on pattern 
               
               
                   
                   
                 metal 22 on 
                 HRI coating 212 
               
               
                   
                   
                 pattern 
                 on pattern 
               
               
                 4 
                 Apply clear primer 
                 Apply clear 
                 Apply clear 
                 Apply primer clear coats 
               
               
                   
                 coats 23a, 23b to 
                 primer coats 
                 primer coats 
                 23a, 23b to top and 
               
               
                   
                 top and bottom 
                 23a, 23b to top 
                 23a, 23b to top 
                 bottom Where primer 
               
               
                   
                 Thickness: 
                 and bottom 
                 and bottom 
                 coat 23a, 23b 
               
               
                   
                 .00002-.0002 
                 Thickness: 
                 Thickness: 
                 Thickness: 
               
               
                   
                   
                 .00002-.0002 
                 .00002-.0002 
                 .00002-.0002 
               
               
                 5. 
                 Form clear PE 
                 Form clear PE 
                 Form clear PE 
                 Form clear PE adhesive 
               
               
                   
                 adhesive layers 24a, 
                 adhesive layers 
                 adhesive layers 
                 layers 24a, 24b fairly 
               
               
                   
                 24b-fairly thick, 
                 24a, 24b fairly 
                 24a, 24b fairly 
                 thick, sticky 
               
               
                   
                 sticky 
                 thick, sticky 
                 thick, sticky 
                 Thickness: 
               
               
                   
                 Thickness: 
                 Thickness: 
                 Thickness: 
                 .0005-.005 
               
               
                   
                 .0005-.005 
                 .0005-.005 
                 .0005-.005 
               
               
                 6. 
                 Form clear buffer 
                 Form clear 
                 Form clear 
                 Form clear buffer layer 
               
               
                   
                 layer 25a, 25b of 
                 buffer layer 
                 buffer layer 
                 25a, 25b of PVC material 
               
               
                   
                 PVC material 
                 25a, 25b of 
                 25a, 25b of 
                 thickness 
               
               
                   
                 thickness 
                 PVC material 
                 PVC material 
                 .0008-.005 
               
               
                   
                 .0008-.005 
                 thickness 
                 thickness 
               
               
                   
                   
                 .0008-.005 
                 .0008-.005 
               
               
                 7. 
                 Form clear white 
                 Form clear 
                 Form clear 
                 Form clear white PVC 
               
               
                   
                 PVC layer white PVC 
                 white PVC layer 
                 white PVC layer 
                 layer 27a, 27b 
               
               
                   
                 layer 27a, 27b 
                 27a, 27b 
                 27a, 27b 
                 Thickness .004 to .012 
               
               
                   
                 Thickness .004 to 
                 Thickness .004 
                 Thickness .004 
               
               
                   
                 .012 
                 to .012 
                 to .012 
               
               
                 8. 
                 Form PVC 
                 Form PVC 
                 Form PVC 
                 Form PVC laminating 
               
               
                   
                 laminating film 29a, 
                 laminating film 
                 laminating film 
                 film 29a, 29b 
               
               
                   
                 29b 
                 29a, 29b 
                 29a, 29b 
                 Thickness .0008 to .005 
               
               
                   
                 Thickness .0008 to 
                 Thickness 
                 Thickness 
               
               
                   
                 .005 
                 .0008 to .005 —   
                 .0008 to .005 
               
               
                   
               
               
                 All dimensions in inches