Abstract:
A lamination plate assembly for use in the manufacture of plastic lenticular cards includes a front lamination plate with first and second opposing planar surfaces. The front lamination plate is shaped to define a plurality of transverse bores that are arranged in a grid. Each bore in the front lamination plate is dimensioned to fittingly receive a corresponding, disc-shaped metal insert in a flush relationship relative thereto, with each insert preferably retained within its associated bore using an appropriate bonding agent. The lamination plate assembly additionally includes a bore-free, back lamination plate with first and second opposing planar surfaces, the back lamination plate being stacked front-to-back against the front lamination plate. The exposed surface of each insert includes a lenticular lens structure, such as an array of parallel, semi-cylindrical grooves or notches, which together create a corresponding lenticular lens structure in a multilayered plastic card sheet produced during lamination.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to the manufacture of plastic cards and more particularly to the manufacture of plastic cards that include a lenticular device. 
       BACKGROUND OF THE INVENTION 
       [0002]    Plastic cards are well known in the art and are commonly constructed for use as, inter alia, financial cards (e.g., credit cards, debit cards and the like), commercial cards (e.g., gift cards, membership cards, loyalty cards, phone cards and the like), identification cards (e.g., drivers licenses and the like), and security cards (e.g., key cards, access cards and the like). 
         [0003]    For aesthetic and/or security purposes, plastic cards are commonly provided with a lenticular device (also referred to herein as a lenticular element). A lenticular device relies upon a form of printing technology in which a lenticular lens is integrated into the card structure and is used to produce either (i) an image with offset layers that together produce a 3D effect and/or (ii) multiple images, each of which is viewable from a particular angle that together can be used to create a particular effect (e.g., a motion, or animation, effect). 
         [0004]    Referring now to  FIGS. 1(   a ) and  1 ( b ), there are shown top perspective and section views, respectively, of a prior art plastic card  11  that is designed to include a lenticular device  13 , this type of card being commonly referred to in the art simply as a lenticular card. In the present example, plastic card  11  is shown comprising an intermediate layer  15  that is disposed between a top layer  17  and a bottom layer  19 , further information relating to layers  15 ,  17  and  19  to be described in detail below. 
         [0005]    Lenticular device  13  is represented herein as a small oval-shaped element that is disposed in one corner of card  11  (e.g., for security purposes). As seen most clearly in  FIG. 1(   b ), lenticular device  13  includes a lenticular lens structure  21  that is formed into top surface of top layer  17 . Lenticular lens structure  21  includes a series, or array, of thin, raised, semi-cylindrical lenses that extend transversely across top layer  17  in a parallel relationship. 
         [0006]    It should be noted that because the array of semi-cylindrical lenses extends parallel to the lateral axis of card  11 , lenticular device  13  is referred to in the industry as having a changeable laser image, or CLI, lenticular structure. By contrast, if the array of lenses were alternatively designed to extend in parallel with the longitudinal axis of card  11 , the resultant lenticular device would be referred to in the industry as having a multiple laser image, or MLI, lenticular structure. 
         [0007]    It should also be noted that although the array of semi-cylindrical lenses is represented herein as being raised above the top surface of top layer  17 , lenticular devices are also commonly constructed with an array of semi-cylindrical lenses that is embedded beneath the top surface of layer  17  (i.e., such that the apex of each lens lies flush with top surface of layer  17 ). 
         [0008]    A lenticular image  23  is represented herein as being printed onto card  11  beneath lenticular lens structure  21  (i.e., sub-surface). Commonly, lenticular image  23  is printed onto card  11  upon completion of its manufacture. For example, a traditional laser may be utilized to print lenticular image  23  beneath lenticular lens structure  21 , the depth of printed image  23  being regulated through modulation of the focal length and intensity of the laser. 
         [0009]    As can be appreciated, lenticular image  23  includes multiple print images that are sliced into thin, parallel strips and, in turn, interlaced in an alternating fashion to form an image array. Due to the construction of lens structure  21 , a first set of selected strips from image  23  can be viewed at a first angle and a second set of selected strips from image  23  can be viewed at a second angle. In this manner, lenticular image  23  achieves its desired multi-dimensional and/or animated effect. 
         [0010]    Referring now to  FIG. 2 , transaction card  11  is typically mass-produced by fusing together one or more enlarged, separate sheets of durable plastic material, such as polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS) or polycarbonate, to form a unitary structure. In a subsequent manufacturing step, a plurality of individual cards (typically 24-96 cards) are then stamped, punched or otherwise separated from the unitary plastic structure. 
         [0011]    For instance, an enlarged intermediate, or filler, sheet  25  is commonly provided that is often print-receptive on at least one of its surfaces. In addition, a top transparent overlay sheet  27  and a bottom transparent overlay sheet  29  are disposed on opposing sides of sheet  25  for protective purposes. Together, sheets  25 ,  27 , and  29  as well as any ink layers printed thereon preferably provide card  11  with an overall thickness that is in compliance with industry guidelines. 
         [0012]    The plurality of separate sheets  25 ,  27  and  29  is then traditionally fused together into a single plastic card sheet  31  as part of a lamination process. An automated lamination machine, or laminator, is commonly utilized to apply heat and pressure to multiple stacks of sheets  25 ,  27 , and  29  at the same time (i.e., to maximize production efficiency). Referring now to  FIGS. 3(   a ) and  3 ( b ), there is shown one well known type of lamination book, or cassette,  33  that can be disposed into a laminator in order to simultaneously laminate multiple stacks of sheets  25 ,  27 , and  29  at a time (often as many as 6 to 10 stacks), the cassette  33  being shown upon completion of the lamination process. In other words, each stack of sheets  25 ,  27  and  29  is shown already fused together to form a corresponding unitary card sheet  31 . 
         [0013]    As can be seen, cassette  33  comprises a plurality of thin, very high gloss, metal lamination plates  35 , with each card sheet  31  sandwiched between an opposing pair of plates  35 . Together, plates  35  and sheets  31  are alternatively arranged and held firmly together as a stack by a pair of outer heated platens  37 . Accordingly, it is to be understood that with cassette  33  disposed in a laminator, the heat and pressure applied to platens  37  (as represented by arrows A in  FIG. 3(   b )) is, in turn, transferred to metal lamination plates  35 . Due to its high gloss construction, lamination plates  35  fuse together each set of sheets  25 ,  27 , and  29  into a unitary card sheet  31  that has a high gloss appearance. Upon completion of the lamination process, each unitary card sheet  31  is manually removed from cassette  33  and, in turn, stamped to form a plurality of individual transaction cards. 
         [0014]    To produce a transaction card  11  with a lenticular device  13 , selected lamination plates  35  are provided with a plurality of lenticular patches  39 , each lenticular patch  39  creating a corresponding lenticular lens structure  21  in card sheet  31  during the lamination process. Specifically, referring now to  FIG. 4(   a ), there is shown a lamination plate  35  that includes a flat, high gloss, front surface  41  and a flat, high gloss, rear surface  43 . Lamination plate  35  additionally includes a plurality of oval lenticular patches  39  that are formed into front surface  41  at specified locations. As seen most clearly in  FIG. 4(   b ), each lenticular patch  39  includes an array of adjacent semicircular grooves  45  that extend transversely within its oval-shaped periphery in a parallel relationship. 
         [0015]    Lamination plates of the type described above that are traditionally used to manufacture plastic cards that include a lenticular device have been found to suffer from a couple notable drawbacks. 
         [0016]    As a first drawback, it is to be understood that each lenticular patch  39  in lamination plate  35  is typically formed through a time-consuming laser engraving, or etching, process (due to the sensitive nature of high gloss front surface  41 ). As a consequence, it is to be understood that the cost associated with an etched lamination plate (e.g., of the type shown in  FIG. 4(   a )) is considerably more expensive than the cost associated with a non-etched plate (often 30 times more expensive). Furthermore, because each lamination cassette  33  that is used to mass-produce lenticular-type plastic cards requires a considerable number of etched lamination plates, the overall cost associated with producing lenticular cards is often found to be prohibitively excessive, which is highly undesirable. 
         [0017]    As a second drawback, it is to be understood that the intricate nature of each lenticular patch  39  in lamination plate  35  must be maintained in order to produce a plastic card with a properly functioning lenticular device. If a single lenticular patch  39  is either improperly formed during its initial manufacture or damaged subsequently during routine use, the entire lamination plate  35  is typically discarded, which is highly undesirable. 
       BRIEF SUMMARY OF THE INVENTION 
       [0018]    It is an object of the present invention to provide a new and improved lamination plate for use in manufacturing a plastic card with a lenticular device. 
         [0019]    It is another object of the present invention to provide a lamination plate of the type as described above that includes one or more lenticular patches, each lenticular patch creating a corresponding lens structure in a card sheet produced during lamination. 
         [0020]    It is yet another object of the present invention to provide a lamination plate of the type as described above that is inexpensive to manufacture, has a limited number of parts, and is easy to use. 
         [0021]    It is yet still another object of the present invention to provide a lamination plate of the type as described above that enables damaged lenticular patches in the lamination plate to be easily repaired. 
         [0022]    Accordingly, as a principal feature of the present invention, there is provided a lamination plate assembly, comprising (a) a first lamination plate comprising first and second opposing surfaces, the first lamination plate being shaped to define one or more bores that extend at least partially into the first surface, and (b) one or more inserts, each of the one or more inserts being dimensioned for insertion into a corresponding bore in the first lamination plate, each insert having a first surface and a second surface, wherein the first surface of each of the plurality of inserts is shaped to include a lenticular lens structure. 
         [0023]    Various other features and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings which form a part thereof, and in which is shown by way of illustration, various embodiments for practicing the invention. The embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    In the drawings wherein like reference numerals represent like parts: 
           [0025]      FIG. 1(   a ) is a top perspective view of a plastic card with a lenticular device; 
           [0026]      FIG. 1(   b ) is an enlarged, fragmentary, section view of the plastic card shown in  FIG. 1(   a ), taken along lines  1 B- 1 B; 
           [0027]      FIG. 2  is a top exploded perspective view of an enlarged plastic card sheet that is used to construct one or more plastic cards of the type shown in  FIG. 1 ; 
           [0028]      FIG. 3(   a ) is a top perspective view of a lamination cassette that is used in the art to constructed one or more plastic cards of the type shown in  FIG. 1 ; 
           [0029]      FIG. 3(   b ) is a top section view of the lamination cassette shown in  FIG. 3(   a ), taken along lines  3 B- 3 B; 
           [0030]      FIG. 4(   a ) is a front perspective view of one of the lamination plates from the lamination cassette shown in  FIG. 3(   a ); 
           [0031]      FIG. 4(   b ) is an enlarged, fragmentary section view of the lamination plate shown in  FIG. 4(   a ), taken along lines  4 B- 4 B; 
           [0032]      FIG. 5  is an exploded, front perspective view of a lamination plate assembly constructed according to the teachings of the present invention; 
           [0033]      FIG. 6  is an enlarged, fragmentary, exploded, front perspective view of the front lamination plate and one of the lenticular inserts shown in  FIG. 5 ; 
           [0034]      FIG. 7  is an enlarged, fragmentary, assembled section view of the front lamination plate and lenticular insert shown in  FIG. 6 ; 
           [0035]      FIG. 8  is a top section view of a lamination cassette that utilizes multiple lamination plate assemblies of the type shown  FIG. 5  to construct a plurality of plastic cards of the type shown in  FIG. 1 ; and 
           [0036]      FIG. 9  is an enlarged, fragmentary, assembled section view of a design modification to the front lamination plate and lenticular insert shown in  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Lamination Plate Assembly  111   
       [0037]    Referring now to  FIG. 5 , there is shown a lamination plate assembly that is constructed according to the teachings of the present invention, the lamination plate assembly being identified generally by reference numeral  111 . As will be described in detail below, lamination plate assembly  111  is designed primarily for use in the manufacture of plastic cards  11  that include a lenticular device  13 . 
         [0038]    Lamination plate assembly  111  includes a front lamination plate  113 , a plurality of insertable lenticular patches, or inserts,  115  fittingly disposed into front lamination plate  113 , and an optional back lamination plate  117  disposed against the rear surface of front lamination plate  113 . As will be described further below, lamination plate assembly  111  is designed for use within a low-cost lamination cassette that can fed into a lamination machine to produce at least one enlarged card sheet  31  from which can be separated a plurality of individual lenticular-type plastic cards  11 . 
         [0039]    Front lamination plate  113  is preferably constructed as enlarged, generally rectangular plate that includes a smooth, high gloss, and flat front surface  119  and a smooth, high gloss, and flat rear surface  121 . Preferably, lamination plate  113  is constructed out of any rigid, durable and thermally conductive material, such as metal. 
         [0040]    A plurality of oval bores  123  is formed into lamination plate  113 , each bore  123  extending transversely through the entirety of plate  113  from front planar surface  119  to rear planar surface  121 , as seen most clearly in  FIG. 6 . Bores  123  are preferably formed into lamination plate  113  using any relatively inexpensive bore forming process. For instance, bores  123  may be formed into lamination plate  113  through a machine stamping process. In the present example, nine separate bores  123  are arranged in plate  113  within a grid of three equidistantly-spaced columns and three equidistantly-spaced rows, for reasons to become apparent below. 
         [0041]    As referenced briefly above, lamination plate assembly  111  includes a plurality of lenticular inserts  115 , each insert  115  being dimensioned for fitted insertion within a corresponding bore  123  in front lamination plate  113 . Each lenticular insert  115  is preferably in the form of an oval, metal disc that includes a front surface  125  and a rear surface  127 . As seen most clearly in  FIGS. 6 and 7 , front surface  125  is textured, or shaped, to include an array of adjacent, semicircular, lateral grooves  129  that extend in a parallel relationship. 
         [0042]    Although represented herein as inlayed, or subsurface, grooves  129 , it is to be understood that grooves  129  could alternatively be raised (i.e., above front surface  125 ) without departing from the spirit of the present invention. Furthermore, although grooves  129  are represented herein as extending laterally, or transversely, across front surface  125 , it is to be understood that grooves  129  could extend longitudinally (i.e., parallel to its longitudinal axis) without departing from the spirit of the present invention. 
         [0043]    Preferably, inserts  115  are mass-produced as part of a designated manufacturing process. For instance, a press tool with a hardened die that is engraved with the particular pattern that compliments grooves  129  could be used to (i) punch out an oval shaped disc from a metal sheet and (ii) simultaneously stamp its front surface with the particular MLI/CLI lenticular lens structure (i.e., the aforementioned pattern of grooves  129 ). In this manner, a supply of lenticular inserts  115  could be mass-produced in a relatively inexpensive fashion. 
         [0044]    It should be noted that inserts  115  need not be provided with its lenticular lens structure using the aforementioned stamping process. Rather, it is to be understood that alternative, cost-effective means for forming the lenticular lens structure into each insert  115  could be readily accomplished (e.g., through machine grinding, milling, ablating or the like) without departing from the spirit of the present invention. 
         [0045]    As seen most clearly in  FIG. 7 , each insert  115  is preferably fittingly disposed within a corresponding bore  123  in lamination plate  113 , with rear surface  127  of insert  115  lying generally flush with rear surface  121  of plate  113  and front surface  125  of insert  115  lying co-planar with front surface  119  of plate  113 . Insert  115  is permanently retained within bore  123  by securing at least a portion of the periphery of rear surface  127  of insert  115  to rear surface  121  of plate  113  using at least one bonding agent  131 , such as an adhesive, solder, or other suitable securement means. 
         [0046]    It is important to note that each insert  115  is permanently secured to lamination plate  113  about rear surface  127 . As a result, the high gloss, front surface  119  of lamination plate  113  remains in its pristine form and thereby avoids being subjected to potentially harmful scratches or other similar damage. 
         [0047]    At the same time, it should be noted that surface imperfections may be created in rear surface  121  of lamination plate  113  during the process of securing each insert  115  within its corresponding bore  123 . The introduction of these surface imperfections in rear surface  121  of lamination plate  113  would, in turn, create similar imperfections in a card sheet  31  that is disposed in direct contact therewith. 
         [0048]    Accordingly, an optional back plate  117  can be utilized to resolve, or smooth-out, surface imperfections created in rear surface  121  of lamination plate  113 , as can be seen in  FIG. 5 . Similar to front lamination plate  113 , back lamination plate  117  is preferably constructed as enlarged, generally rectangular plate that includes a smooth, high gloss, and flat front surface  133  and a smooth, high gloss, and flat rear surface  135 , plate  117  being constructed out of any rigid, durable and thermally conductive material, such as metal. 
         [0049]    Back plate  117  differs from front plate  113  in that back plate  117  is an entirely solid member that does not include complimentary bores  123  and inserts  115 . Accordingly, by disposing front planar surface  133  of back plate  117  directly against rear planar surface  121  of front lamination plate  113 , any surface imperfections in rear surface  121  are effectively covered by back plate  117 . In this capacity, it is to be understood that pristine rear surface  135  of back plate  117  serves as the contact lamination surface in place of non-pristine rear surface  121  of front plate  113 . 
       Mass-Production of Lenticular Cards  11  using Lamination Plate Assemblies  111   
       [0050]    Referring now to  FIG. 8 , there is shown a lamination cassette  137  that utilizes selected components from several lamination plate assemblies  111  to form multiple, enlarged card sheets  31  from which can be separated a plurality of individual lenticular-style cards  11 . Specifically, in the present example, three separate card sheets  31 - 1 ,  31 - 2  and  31 - 3  are shown. First card sheet  31 - 1  is sandwiched between rear surface  135 - 1  of a first back lamination plate  117 - 1  and front surface  119 - 1  of a first front lamination plate  113 - 1 . Second card sheet  31 - 2  is sandwiched between rear surface  135 - 2  of a second back lamination plate  117 - 2 , which is disposed directly against rear surface  121 - 1  of first front lamination plate  113 - 1 , and front surface  119 - 2  of a second front lamination plate  113 - 2 . Third card sheet  31 - 3  is sandwiched between rear surface  135 - 3  of a third back lamination plate  117 - 3 , which is disposed directly against rear surface  121 - 2  of second front lamination plate  113 - 2 , and front surface  119 - 3  of a third front lamination plate  113 - 3 . Lamination cassette  131  additionally includes a pair of heated outer platens  139 - 1  and  139 - 1 , with first platen  139 - 1  disposed against front surface  133 - 1  of first back lamination plate  117 - 1  and second platen  139 - 2  disposed against rear surface  121 - 3  of third front lamination plate  113 - 3 . 
         [0051]    It is to be understood that with cassette  137  loaded into a lamination machine, the heat and pressure applied to outer platens  139  (as represented by arrows B) is, in turn, transferred to each of lamination plates  113  and  117 . As such, each card sheet  31  disposed within cassette  137  is fused as a unitary member from its original separate plastic layers (e.g., sheets  25 ,  27  and  29 ). As referenced above, the inclusion of back plates  117 - 2  and  117 - 3  prevents surface defects that are created in the rear of front plates  113 - 1  and  113 - 2 , respectively, during the process of permanently securing inserts  115  thereto from marring or otherwise damaging the opposing face of the adjacent card sheet  31 . 
         [0052]    The inclusion of inserts  115  in each lamination plate  113  creates a pattern of lenticular lens structures  21  in the opposing face of the card sheet  31  in direct contact thereagainst. As a result, upon completion of the lamination process, lamination cassette  133  is removed from the lamination machine. Each card sheet  31  is then withdrawn from lamination cassette  133 , with nine lenticular lens structures  21  formed in one surface of each card sheet  31  in the defined pattern, or grid, which corresponds to the arrangement of inserts  115  in lamination plate  113 . 
         [0053]    The resultant card sheet  31  can then be stamped to create nine separate plastic cards  11 , each card  11  being provided with an oval-shaped lenticular lens structure  21  in a common location. In a subsequent step, lenticular image  23  is preferably printed on each card  11  (e.g., beneath each lenticular lens structure  21  using a sub-surface laser printing device) to create a lenticular device  13 , which is a principal object of the present invention. 
       Additional Embodiments and Design Modifications 
       [0054]    The embodiment shown above is intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims. 
         [0055]    For example, in the present example, each card sheet  31  produced from cassette  137  includes nine, separate, oval-shaped, lenticular lens structures  21  in its front surface. However, it should be noted that the number, shape and arrangement of inserts  115  in lamination plate  113  (and, as a result, the number, shape and arrangement of lens structures  21  in each card sheet  31  produced therefrom) could be modified without departing from the spirit of the present invention. In particular, it is to be understood that the number of inserts  115  disposed within lamination plate  113  could be increased (e.g., to 24 or 96 inserts per plate) to increase the productivity and overall efficiency of the card manufacturing process. 
         [0056]    As another example, it should be noted that inserts  115  are not limited for use with a particular type or style of lamination plate  113 . Rather, it is to be understood that inserts  115  could be secured to modified lamination plates in alternative arrangements, or patterns, without departing from the spirit of the present invention in order to create a wide variety of lenticular card styles. In this manner, the particular location of the lenticular lens structure in a plastic card could be modified by simply forming each insert-receiving bore in a different position within a new lamination plate. By contrast, the traditional method for modifying the location a lenticular lens structure within a plastic card requires that an entirely new set of laser-etched lamination plates be manufactured, which is considerably expensive. 
         [0057]    As another example, it should be noted that lamination cassette  137  is not limited to particular number and arrangement of front and back lamination plates  113  and  117  represented herein. Rather, it is to be understood that additional front and back lamination plates  113  and  117  could be incorporated into cassette  133  in a similar arrangement to allow for the simultaneous lamination of additional card sheets  31  (e.g., to produce as many as 6 to 10 card sheets from each lamination cassette). 
         [0058]    As another example, it should be noted that each bore  123  need not extend transversely through the entirety of front lamination plate  113 . Specifically, referring now to  FIG. 9 , there is shown an enlarged, fragmentary, section view of a design modification to the lamination plate  113  and lenticular insert  115  shown in  FIG. 7 . 
         [0059]    As can be seen, a modified lamination plate  213  is provided that includes a flat front surface  219  and a flat rear surface  221 . A bore, or cavity,  223  is partially routed, or otherwise formed, into front surface  219 . In turn, a lenticular insert  215  is fittingly disposed within bore  223  in lamination plate  213  and is secured thereto using a bonding agent  231 , such as such an adhesive, solder, or other suitable securement means. As can be appreciated, inserts  215  differ from inserts  115  primarily in that each insert  215  is reduced in its thickness to the extent that its front surface  225  lies substantially flush with front surface  219  of lamination plate  213 . Furthermore, it is to be understood that by only partially routing bore  223  into lamination plate  213 , rear surface  221  of lamination plate  213  is not disturbed, thereby eliminating the need for a corresponding back plate  117 .