Patent Publication Number: US-2023161329-A1

Title: Card having metallic core layer and systems and methods for card manufacturing

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 16/248,256, filed Jan. 15, 2019, entitled “CARD HAVING METALLIC CORE LAYER AND SYSTEMS AND METHODS FOR CARD MANUFACTURING”, which is a continuation-in-part of International Patent Application PCT/US2018/045600, filed Aug. 7, 2018, entitled “CARD HAVING METALLIC CORE LAYER AND SYSTEMS AND METHODS FOR CARD MANUFACTURING,” which claimed the benefit of U.S. Provisional Application No. 62/541,909, filed on Aug. 7, 2017, entitled “SYSTEMS AND METHODS FOR CARD MANUFACTURING,” and U.S. Provisional Application No. 62/568,517, filed Oct. 5, 2017, entitled “SYSTEMS AND METHODS FOR CARD MANUFACTURING,” and this application claims the benefit of U.S. Provisional Application Ser. No. 62/617,863, filed on Jan. 16, 2018, entitled “CARD HAVING METALLIC CORE LAYER AND SYSTEMS AND METHODS FOR CARD MANUFACTURING,” each of which is incorporated herein in its respective entirety. 
    
    
     BACKGROUND 
     Information carrying cards provide identification, authentication, data storage and application processing. Such cards or parts include key cards, identification cards, telephone cards, credit cards, bankcards, tags, bar code strips, other smart cards and the like. 
     Current information carrying cards use plastic or other polymer material cores. Current materials fail to provide a desired tactile response and strength. For example, information carrying cards need to withstand flexing to protect identifying components from damage as well as offer good durability during use. In addition, information carrying cards should be appealing, in terms of appearance and feel, to the end user, in order to facilitate use and adoption of the information carrying card. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
         FIG.  1    illustrates a cross-sectional view of a layer structure of an information carrying card, in accordance with some embodiments. 
         FIG.  2    illustrates a cross-sectional view of an electronics layer of an information carrying card, in accordance with some embodiments. 
         FIG.  3    illustrates an information carrying card having an EMV (Europay MasterCard Visa) chip embedded therein, in accordance with some embodiments. 
         FIG.  4 A  illustrates a plan view of a frame having a plurality of cavities, in accordance with some embodiments. 
         FIG.  4 B  illustrates a plan view of a frame of the sheet of  FIG.  4 A  with a plurality of core layers disposed in the cavities, in accordance with some embodiments. 
         FIG.  5    illustrates a core layer having a discontinuity extending from a first edge of the core layer, in accordance with some embodiments. 
         FIG.  6    illustrates a flow diagram of a method of forming a prelaminate, in accordance with some embodiments. 
         FIG.  7    illustrates a detail view of a plurality of core layers, in accordance with some embodiments. 
         FIG.  8    illustrates a flow diagram of a method of forming a laminate, in accordance with some embodiments. 
         FIG.  9    illustrates a card manufacturing system including a locating system and a singulation system, in accordance with some embodiments. 
         FIG.  10 A  illustrates a plan view of a laminate sheet having registration markings corresponding to a position of each card in the laminate sheet, in accordance with some embodiments. 
         FIG.  10 B  illustrates a plan view of a laminate sheet having reference registration markings formed thereon, in accordance with some embodiments. 
         FIG.  11    illustrates an isometric view of a card manufacturing system, in accordance with some embodiments. 
         FIG.  12    illustrates a transport arm of the card manufacturing system of  FIG.  11    engaging a laminate, in accordance with some embodiments. 
         FIG.  13    illustrates a vacuum fixture of the card manufacturing system of  FIG.  11   , in accordance with some embodiments. 
         FIG.  14    illustrates an isometric view of the card manufacturing system of  FIG.  11   , in accordance with some embodiments. 
         FIG.  15    illustrates vacuum cups of the transport arm engaged with cards and the frame of the laminate, in accordance with some embodiments. 
         FIG.  16    illustrates the frame being transported to a discard station of the card manufacturing system of  FIG.  11   , in accordance with some embodiments. 
         FIG.  17    illustrates the cards being transported to the unload station of the card manufacturing system, in accordance with some embodiments. 
         FIG.  18    is a flowchart illustrating a method of forming a card using the card manufacturing system of  FIG.  1   , in accordance with some embodiments. 
         FIG.  19    illustrates a block-diagram of a control system of a card manufacturing system, in accordance with some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The description of the preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In this description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top,” “bottom,” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively coupled” is such an attachment, coupling, or connection that allows the pertinent structures to operate as intended by virtue of that relationship. Terms referring to electrical connections, such as “electrically connected,” “electrically coupled,” “in signal communication with,” etc. refer to a relationship wherein an electrical signal may travel from one component to another component over any suitable wired or wireless channel or connection. 
     The following disclosure provides many different embodiments, or examples, for implementing different features of the subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
     For brevity, unless expressly stated otherwise, references to “information carrying card” or “smart card” made throughout this description are intended to encompass at least key cards, identification cards, telephone cards, credit cards, bankcards, power cards, tags, bar code strips, any part comprising an integrated circuit (IC), and the like. “Information carrying card” or “smart card” also includes a wide variety of shapes, which include but are not limited to rectangular sheets, circular sheets, strips, rods and rings. “Information carrying card” or “smart card” also includes any information carrying parts of both “contact” and “contactless” modes. “Information carrying card” or “smart card” also encompasses any information carrying cards with or without an on-board power supply. An information carrying card comprising a power supply is also referred to as a “power card.” The present disclosure generally relates to laminates for an information carrying card, resulting information carrying cards, and methods of making the same. 
     Information Carrying Card 
       FIG.  1    illustrates a cross-sectional view of an information carrying card, in accordance with some embodiments. In some embodiments, the information carrying card  52  includes a core layer  54 , one or more printable films  56 , and/or one or more transparent films  58 . The printable films  56  and transparent films  58  can be, for example formed from a thermoplastic or any other appropriate material. In one embodiment, a printable film  56  and a transparent film  58  are disposed on either side of the core layer  54 . In other embodiments, the information carrying card  52  includes a printable film  56  and a transparent film  58  on only one side of the core layer  54 . In some embodiments, the information carrying card  52  includes one or more dimensions defined by one or more industry or commercial standards, such as an ISO/IEC 7810 standard. For example, an ID-1 type smart card, which is used for most banking and ID cards, has standardized dimensions of 85.6×53.98 mm, although it will be appreciated that the information carrying cards  52  discussed herein can have any suitable dimensions. 
     In some embodiments, the core layer  54  extends from a first edge  60  of the information carrying card  52  to an opposite, second edge  62  of the information carrying card  52 . The core layer  54  can include one or more materials. For example, in some embodiments the core layer is constructed of a metallic material and/or a partially metallic material. The metallic material can be stainless steel—such as 305 stainless steel, tungsten, platinum, or any other appropriate material. As another example, in some embodiments, the core layer  54  includes a high density and/or a plastic material (such as a polyvinyl chloride (PVC) material and/or a polyethylene terephthalate (PET) material). The presence of a metallic, high density, and/or plastic core layer  54  increases the durability and longevity of the information carrying card  52 . Additionally, the density or weight of an information carrying card  52  including a metallic and/or high density core layer  54  may be desirable to users. The edges of the information carrying card  52  can be finished with a variety of machining techniques to provide a desired surface finish, as discussed in greater detail below. By providing an aesthetically appealing edge  60 ,  62 , the information carrying card  52  may be desirable for customers and potential customers of a bank or other financial institution. In addition, the finished edges  60 ,  62  prevent or limit damage to a user and/or the information carrying card  52  itself. To the extent embodiments are discussed herein including a first material in the core layer  54  (e.g., a metal material), it will be appreciated that such embodiments are generally applicable to other materials (such as high density and/or plastic materials) and are within the scope of this disclosure. 
     In some embodiments, an outer layer of an information carrying card  52  includes a transparent film  58 . Examples of transparent film  58  include but are not limited to PVC (polyvinyl chloride) and PET (polyethylene terephthalate). Although specific embodiments of transparent films  58  are discussed herein, it will be appreciated that the transparent film  58  can include any suitable transparent material. In some embodiments, the transparent film  58  may be omitted and/or combined with one or more additional layers. 
     In some embodiments, the printable film  56  is an imaging receiving layer. Words, images, and/or other elements can be printed onto the printable film  56  before or during a process of making an information carrying card  52 . In some embodiments, the printable film  56  is not transparent, and contains some pigments such as white pigments, color pigments, etc. Although specific embodiments of printable films  56  are discussed herein, it will be appreciated that any suitable printable film or graphic layer can be positioned between the core layer  54  and a transparent film  58 . In some embodiments, the printable film  56  may be omitted and/or combined with one or more additional layers. 
     Additionally, as seen in  FIG.  2   , in some embodiments, the information carrying card  52  can include an electronic layer  55  comprising electronic components  10 , such as a printed circuit board (PCB)  11 , supporting film  12  and interconnects  14 . The electronic components  10  are connected by the interconnects  14 . The electronic components  10  are embedded or surface-mounted on the supporting film  12 . In some embodiments, the electronic components  10  are disposed on an inlay layer  8 . The inlay layer  8  can be disposed within a housing layer  6 . The housing layer  6  can be constructed of a thermoplastic material. A polymer composition (not shown) can fill voids and remaining spaces between the inlay layer  8  and the housing layer  6 . In some embodiments, the polymer composition  16  is a cross-linked polymer composition. The polymer composition  16  can directly contact the outer surface of the electronic components  10 . The electronic layer  55  can be configured and manufactured as described in U.S. Pat. No. 9,275,321, which is incorporated herein in its entirety. 
     In some embodiments, the electronic layer  55  is disposed between the core layer  54  and one of the printable films  56 . The electronic layer  55  can enable the card  52  to include advanced security features, such as one-time passwords. For example, the smart card can include the security features described in U.S. Pat. No. 9,004,365, which is incorporated herein in its entirety. As shown in  FIG.  3   , in some embodiments, the information carrying card  52  includes an EMV chip  64  and/or other embedded objects including three-dimensional objects. Such features allow the information carrying cards  52  to include traditional magnetic strips, EMV chips  64  as well as contactless payment technologies. The information carrying card  52  can also include advanced security features such as on-demand CVV generation. 
     Prelam Formation 
       FIG.  4 A  illustrates a frame  65 , in accordance with at least one embodiment. The frame  65  can be constructed of PVC and/or other appropriate material and defines a plurality of cavities  66 . Each of the plurality of cavities  66  is sized and configured to accept a core layer  54 . 
     As shown in  FIG.  4 B , a prelam  67  can be formed by positioning a core layer  54  in each of the cavities  66  of the frame  65 . The core layers  54  can be positioned in the cavities  66  manually or, for example, by an automated pick and place system. The core layers  54  can be secured in place within the cavities  66  by any appropriate means. For example, the core layers  54  can be held in place by adhesives, tape, and/or other means. In one embodiment, the frame  65  and core layers  54  are maintained in relative position by one or more carrier sheets adhered to the frame  65  and core layers  54 . The prelam  67  shown in  FIG.  4 B  is a “36-up” sheet, i.e., consisting of six rows of six core layers. This arrangement provides for a high throughput while minimizing the amount of material that is removed during a singulation process (discussed in greater detail below). It should be understood that other arrangements of core layers  54  are contemplated and are within the scope of this disclosure. Advantageously, the singulation process described in further detail herein allows for flexibility in shape, orientation, and quantity of core layers  54 . 
     As shown in  FIG.  5   , in some embodiments, the core layer  54  can include internal features which allow the placement of security and/or decorative features in an information carrying card  52 . For example, the core layer  54  includes an internal cavity  72  for placement of an EMV chip, a decorative element such as an inlay, and/or any other suitable element. 
     In some embodiments, one or more printed circuit elements can be disposed within each of the internal cavities  72  formed in the core layer  54 . For example, in the various embodiments, an antenna including one or more circular coils can be disposed within the internal cavity  72 , although it will be appreciated that the antenna can have any suitable shape and/or any suitable number of windings (or coils). A plurality of contact points may be configured to electrically couple an active circuit element, such as an integrated circuit, processor, or other system-on-chip (SoC) element to the printed circuit elements formed within the internal cavity  72 . 
     In some embodiments, the one or more printed circuit elements can include a second antenna (not shown). The second antenna can be positioned within the cavity  72  and/or can be positioned in one or more additional cavities (not shown) defined in the core layer  54   a . The second antenna can have a greater and/or lesser antenna area than the first antenna such that the first and second antennas produce different voltages when exposed to the same signal. In some embodiments, the first antenna can control operation of the active circuit element and the second antenna can control operation of additional circuit elements (not shown). 
     In some embodiments, the one or more printed circuit elements are configured to be self-leveling during a credential card formation process. The printed circuit elements are formed within the metal core layer  54  and can be raised and/or lowered during formation of a laminate sheet  50 . For example, in some embodiments, the printed circuit elements can flex out of plane with the respect to the core layer  54  when a filler material is provided within the internal cavity  72 . During some laminate formation processes, the core layer  54  is exposed to and/or immersed in a liquid filler material, and the printed circuit elements are self-leveled (i.e., centered) with respect to the core layer  54 . 
     In some embodiments, the filler material can include any suitable material, such as a moly-based material (e.g., molybdenum), a PVC material, a PET material, and/or any other suitable material. The filler material can be selected to have a similar feel/weight as compared to the core layer  54  to maintain a uniform feel to the card  52 . 
     Surface preparation techniques can be used to improve the adhesion of the printable film  56  and/or transparent film  58  to the core layers  54 . Such preparation can include coating of the core layers  54  with EVA (ethylene-vinyl acetate) or EAA (ethylene acrylic acid). In embodiments in which the core layers  54  are attached to a frame  65  of a different material, the surface preparation of the core layers  54  can be performed before and/or after connection of the core layers  54  to the frame  65 . 
     In at least some embodiments, the core layers  54  are larger in size than the desired information carrying card  52 . The excess material of the core layer  54  allows the information carrying cards  52  to be cut or singulated to a final size after the lamination process, as described further herein. 
     In some embodiments, multiple core layers  54  are connected prior to placement within the frame  65 . The multiple core layers  54  can be etched from a single metal sheet, with the multiple core layers  54  connected by runners. The etched sheet is placed within a frame  65  that includes cavities  66  for the multiple core layers  54  and voids for the connecting runners. In this way, processing and handling of the core layers  54  is simplified. Instead of handling each core layer  54  individually, a single sheet is placed within the frame  65 . The single sheet simplifies handling as well as eases inventory management of the core layers  54 . 
     Referring to  FIG.  6   , a process  80  for forming a prelaminate, in accordance with some embodiments is discussed. At step  82 , a second release film is placed above a first release film. At step  84 , a frame  65  having at least one cavity  66  is obtained. For example, the frame  65  may be formed in conjunction with the process  80  for forming a prelaminate. Alternatively, the frame  65  may be formed prior to executing the process  80  and may be obtained from an inventory store of preformed frames. At step  86 , the frame  65 , having at least one cavity, is placed above the first and second release films. At step  88 , a core layer  54  is placed at least partially into a cavity  66  of the frame  65 . 
     Following step  88 , the process optionally comprises step  90  of “fixing” the core layer  54  on frame  65  using an instant adhesive. For example, in some embodiments, the instant adhesive includes cyanoacrylate, although it will be appreciated that any suitable adhesive can be used. In some embodiments, the core layer  54  is fixed to the frame  65  in a period as short as a few seconds, although it will be appreciated that each adhesive will require a greater and/or lesser adhesion time, depending on one or more environmental, chemical, and/or other factors. 
     At step  92 , a cross-linkable polymer composition is dispensed over the core layer  54  and inside the cavity  66 . In embodiments with an electronic layer  55 , the cross-linkable polymer composition may directly contact the electronic components  10  including active or passive electronic components, e.g., an integrated circuit (IC). In some embodiments, the amount of cross-linkable polymer composition is predetermined and controlled. Any extra material exceeding the top surface of the frame  65  may be removed. In some embodiments, the curable base polymer resin in the cross-linkable polymer composition is urethane acrylate, and the particulate thermoplastic filler in the cross-linkable polymer composition is PVC, a compound or a blend comprising PVC or a vinyl chloride copolymer, or a copolymer of vinyl chloride and at least another monomer such as vinyl ester or vinyl ether, although it will be appreciated that other suitable chemical compositions can be used. 
     In some embodiments, the cross-linkable polymer is configured to fill one or more cavities  72  formed in the core layer  54  and/or the electronics layer  55 . The cross-linkable polymer may fully and/or partially fill each cavity  72 . In some embodiments, one or more elements of the electronic layer  55  are self-leveling such that the one or more elements are positioned at a predetermined midpoint (or other selected point) within the volume of cross-linkable polymer within the cavity  72 . 
     At step  94 , a third release film and a fourth release film are placed on the layered structure to form a sandwich structure. The third release film is placed first followed by the fourth release film. In some embodiments, the third release film is formed from the same material as the second release film, such as a breathable release film. The fourth release film may be formed from the same material as the first release film. In some embodiments, the first and fourth release films are a polytetrafluoroethylene (under the trade name Teflon®) sheet, although it will be appreciated that other films may be used. At step  96 , the layered structure is placed under pressure, e.g., a pressure of less than about 2 MPa. 
     At step  98 , the layered structure is heated under pressure. A suitable temperature would be one that is sufficiently high to partially or fully cure the cross-linkable polymer composition, hot laminating first thermoplastic film, or both. After the heat treatment, the cross-linkable polymer composition forms a solid. Such a cross-linked polymer composition has good adhesion with the frame  65  and the core layer  54  including, optionally, electronic component  10  and supporting film  12 . In some embodiments, the temperature is in the range of 65-232° C. In some embodiments, the temperature is less than 150° C. It will be appreciated that any suitable temperature or temperature range can be used based on the properties of the cross-linked polymer and/or the heat tolerance of one or more components in the layered structure (such as one or more elements in the electronics layer  55 ). 
     In some embodiments, step  98  may be replaced and/or augmented by a step of curing the cross-linkable polymer composition using visible light, UV or other radiation curing. It may also comprise a step of curing via the introduction of moisture or the promotion of other chemical reactions. At optional step  99 , the layered structure is cooled and the first, second, third and fourth release films are removed. After process  80 , the cross-linkable polymer composition is cured so as to yield a solid. After the release films are peeled away, a prelaminate for an information carrying card is formed. The prelaminate comprises a frame  65 , a plurality of core layers  54  and a cured cross-linked polymer composition. The prelaminate may be stored and/or immediately transferred to a card manufacturing system, such as card manufacturing system  2  described in greater detail below. 
     In some embodiments, a frame  65  without cavities  66  is used. In such an embodiment, core layers  54  are positioned on a top surface of the frame  65 . The core layers  54  may be secured to the top surface of the frame  65  by adhesive or other means. Prior to placement, the core layers  54  may be treated, on one or both faces, with EVA or EAA to improve the adhesion of the core layers  54  to the frame  65 . The core layers  54  may be placed manually and visual alignment guides (not shown) may be provided on the frame  65  to ensure that the core layers  54  are placed in the correct location. Alternatively, the core layers  54  can be placed using an automated pick and place system which allows for the accurate placement of the core layers  54 . After placement of the core layers  54  on the frame  65 , an additional layer of EVA or EAA may be placed on the top of the core layers  54 . The bottom layer, core layers  54 , and top layer can then be laminated together to form a subassembly which can be further processed as described herein. 
     In some embodiments, each of the core layers  54  may be individually placed and/or two or more of the plurality of core layers  54  may be connected to adjacent core layers  54  by runners  70  to form a sheet  69  (as shown in  FIG.  7   ). Voids  68  may be present between adjacent core layers  54 . The presence of the voids  68  may allow for flexing or movement of the individual core layers  54  during the manufacturing process without affecting adjacent core layers  54 . This can improve the finish of the information carrying cards  52  produced from such core layers  54 . For example, the ability of the core layers  54  to move and/or flex with respect to one another may prevent warping of the core layers  54 , leading to a finished information carrying card  52  with improved flatness. In addition, because adjacent core layers  54  are only connected by relatively thin runners  70 , singulation of the core layers  54  does not lead to unacceptable heat generation or excessive wearing of machine bits. A plurality of sets of core layers  54  can be placed on the bottom layer, as described above. By providing sets of connected core layers  54 , the processing time and burden is reduced, leading to increased throughput. 
     The sets of core layers  54  can be arranged in any arrangement. For example, the sets may include six core layers  54  connected linearly. Alternatively, the sets can include four or more core layers  54  arranged in a square or rectangular arrangement, as shown in  FIG.  7   . In some embodiments, the runners  70  connect neighboring core layers  54  to maintain the integrity of the sheet  69 . The runners  70  may be positioned at any point along the core layers  54 . For example, as shown in  FIG.  7   , the runners  70  can be approximately centrally located with respect to the core layers  54 . In other embodiments, the runners  70  are offset from the center of the core layers  54 . The runners  70  may have a constant width and/or a variable width along the length of the runners. Each runner  70  in the sheet  69  can have the same width or, alternatively, the runners  70  may be of different widths throughout the sheet  69 . The plurality of core layers  54  can be defined in any suitable manner, such as, for example, etching, machining, and/or other appropriate processes. The core layers  54  and sheet  69  can be constructed from stainless steel, tungsten, gold, platinum, or any other appropriate material. In some embodiments, the metallic sheet  69  can include different alloys or metals formed integrally together, with a first metal defining one or more of the plurality of core layers  54  and a second metal defining the runners  70  and perimeter of the sheet  69 . Although specific embodiments are discussed herein, it will be appreciated that the core layers  54  can include any suitable material and/or combination of materials. 
     Lamination 
       FIG.  8    illustrates an exemplary process  150  of making a laminate  5 , in accordance with some embodiments. In some embodiments, the outer layer of an information carrying card  52  includes a transparent film  58 . Examples of transparent film  58  include but are not limited to PVC, modified PVC, and PET. At step  152 , and with reference to the structure shown in  FIG.  1   , a printable film layer  56  is disposed onto the transparent film  58 . In some embodiments, the printable film  56  is an image receiving layer. Words, images, and/or other graphical elements are printed onto the printable film  56  before or during a process of making a laminate. In some embodiments, the printable film  56  is not transparent, and contains some pigments such as white pigments. 
     In step  154 , a prelaminate  67  is disposed onto the printable thermoplastic layer  56  and the transparent film  58 . In step  156 , a second printable thermoplastic layer  56  is disposed onto the layered structure, followed by a second transparent film  58 . In some embodiments, at least one release film is used on each side of the layered structure. Examples of the release film include a sheet of polytetrafluoroethylene, any other fluoropolymer, silicone, a fluoropolymer or silicone coated film, and/or any other suitable release film. In some embodiments, a breathable release film is used. 
     In step  158 , the layered structure is laminated at a predetermined pressure and a predetermined temperature. In some embodiments, the pressure is less than 2 MPa. The predetermined temperature is selected such that all the films in the layered structure are laminated with good adhesion. In some embodiments, the predetermined temperature is in the range of 65-232° C. In some embodiments, the predetermined temperature is less than 150° C. Although embodiments are discussed herein having specific temperatures or temperature ranges, it will be appreciated that the predetermined temperature can be any temperature configured to laminate the layered structure with good adhesion at the selected pressure. In some embodiments, additional and/or alternative laminating/curing methods can be applied, for example, ultraviolet (UV) curing, etc. 
     In some embodiments, at optional step  160 , a surface treatment method is performed to improve adhesion between two or more layers. Examples of surface treatment methods include but are not limited to plasma treatment and/or corona treatment before hot lamination at step  158 . 
     Singulation Process 
       FIG.  9    illustrates a card manufacturing system  2  including a locating device  100  and a separation device  200 , in accordance with some embodiments. The card manufacturing system  2  is configured to receive one or more laminate sheets  50  (e.g., one or more laminated sheets  50  of information carrying cards  52  manufactured substantially as discussed above) and generate a plurality of physical information carrying cards  52 , such as, for example, credit cards, credential cards, etc. After forming a laminate sheet  50 , the position of the core layers  54  within the laminate may vary. For example, variation in the alignment of the layers during the lamination process can result in one or more core layers  54  having offset or unknown positions. In addition, there may be variations in the placement of the core layers  54  within the frame  65 . As a result, it is necessary to accurately determine the location of the core layers  54  prior to singulating the individual cards. By so doing, the individual cards can be separated such that the edges of the card show an exposed metal edge while at the same time requiring only a small amount of material to be removed from the metal core layers, advantageously minimizing the heat buildup during singulation and minimizing the wear on singulation tools. 
     In some embodiments, the card manufacturing system  2  includes a locating device  100  configured to locate one or more elements within the laminate sheet  50 , for example, the position of each core layer  54  within the laminate sheet  50 . Each of the laminate sheets  50  has a known outer perimeter (e.g., known height and length) and includes a plurality of cards  52  formed integrally therein, for example, according to the formation and lamination process discussed above. Each laminate sheet  50  can have a variable number of cards  52  formed therein and/or each of the cards  52  can have variable dimensions from one or more other cards formed on an individual laminate sheet  50 . In some embodiments, the laminate sheet  50  is a multi-layer laminate including one or more metal, plastic, electronic, image, and/or additional or alternative layers, as described above. In addition, U.S. Pat. No. 9,122,968, issued on Sep. 1, 2015, entitled “Information Carrying Card Comprising a Cross-Linked Polymer Composition, and Method of Making the Same” describes various other embodiments of prelaminate and laminate manufacturing, and is incorporated by reference herein in its entirety. 
     With reference back to  FIG.  9   , the locating device  100  is configured to receive each of the laminate sheets  50  individually and identify the position of each card  52  within the laminate sheet  50  (i.e., inspect the laminate sheet  50 ). The locating device  100  includes a locating modality configured to locate one or more features of each of the cards  52  to identify the position of each card  52  within the laminate sheet  50 . In some embodiments, the locating modality includes an imaging modality configured to image the laminate sheets  50  in a non-visible and/or visible spectrum. For example, in various embodiments, the locating device  100  includes one or more of an x-ray imager, an ultrasonic imager, a nuclear imager, an ultraviolet imager, sonogram (magnetic resonance) and/or any other suitable imager operating outside of the visible spectrum. The locating device  100  may also include a visible spectrum imager, such as a charge-coupled device (CCD), complementary metal-oxide-semiconductor (CMOS), and/or any other suitable digital sensor. 
     In some embodiments, the locating device  100  includes a locating modality configured to identify one or more materials present in each of the plurality of cards  52  but not present in the surrounding material of the laminate sheet  50 . For example, in some embodiments, each of the plurality of cards  52  includes at least one core layer  54  having a first material that is absent from the surrounding material, such as, for example, a metal material, a high-density material, etc. The locating modality is configured to identify the position of the at least one core layer  54  within each of the plurality of cards  52 , for example, using an imaging modality (as discussed above) and/or a non-imaging modality. In some embodiments, the locating modality of the locating device  100  includes a non-imaging detection unit configured to locate the core layers  54  of the laminate sheet  50 . For example, in embodiments including a metal core layer  54 , the non-imaging detection unit can include a metal detector. The non-imaging detection unit can include any unit configured to detect the first material of the core layer  54 . Although embodiments are discussed herein including at least one metallic core layer  54  and non-metal filler material, it will be appreciated that the locating device  100  can be used to identify the locations of core layers constructed of a variety of materials. 
     The locating device  100  is configured to locate each card  52  within the laminated sheet  50  and provide positional guidance to the separation device  200 . The positional guidance can include, but is not limited to, visual spectrum markings at predetermined positions corresponding to each of the plurality of cards in the laminate sheet  50 , one or more markings corresponding to one or more reference locations on the laminate sheet  50  and information for calculating card positions from the reference location, as a mapping (or other digital) file including information regarding positions of each card  52  within the laminate sheet  50  based on markings and/or edge information of the laminate sheet  50 , and/or any other suitable positional guidance. The mapping and/or information files can be stored in tangible, non-transitory memory that can be accessed by the separation device  200  to guide singulation of the individual cards  52 , as discussed in greater detail below. It will be appreciated that the locating device  100  can implement additional, alternative, and/or combinations of marking systems as discussed herein. 
     In some embodiments, the locating device  100  is configured to generate markings  74  and/or other indicators on the laminate sheet  50 . For example, in some embodiments, markings  74   a  correspond to edge positions of each of the plurality of cards  582  within the laminate sheet  50 , as shown in  FIG.  10 A . In the illustrated embodiment, the markings  74   a  include markings corresponding to a first corner and a second corner of each of the cards  52 , although it will be appreciated that the markings  74   a  can correspond to any portion of a card  52 , such as, a partial and/or full perimeter of the card  52 , one or more edges of the card  52 , one or more dimensions of the card  52 , etc. In other embodiments, the markings  74  may correspond to alignment positions, spacing, and/or physical positioning of the plurality of cards  52  within the laminate sheet  50 . For example,  FIG.  10 B  illustrates a laminate sheet  50   a  including a reference marking  74   b  formed thereon. The reference marking  74   b  corresponds to a reference location on the laminate sheet  50   a . The location and/or perimeter of each card  52  in the laminate sheet  52  can be determined based on calculations e.g., vectors, distances, etc.) from the reference marking  74   b.    
     The markings  74  can include visible-spectrum and/or non-visible spectrum markings, such as ink and/or other printable markings formed on a surface of the laminate sheet  50 , etching or other material markings formed on and/or through the laminate sheet  50 , graphics, and/or any other suitable visible and/or non-visible marking. In some embodiments, the markings  74  include reactive materials configured to react to one or more wavelengths, reactive agents, and/or other reactive materials. Although specific embodiments are discussed herein, it will be appreciated that any number of markings (e.g., 1, 2, 3, 4, 5) can be formed on the laminate sheet  50  which can correspond to a portion of a card (such as an edge, corner, center, etc.), a perimeter of a card (e.g., continuous about a perimeter of the card), and/or a predetermined location on the laminate sheet  50  (e.g., one or more reference markings). 
     In some embodiments, visible-spectrum markings  74  include one or more graphics and/or other images formed on one or more of the laminate sheets  50 . The graphics can include any suitable graphic placed on the card, such as finished graphics, partial graphics, etc. The graphics can correspond to and/or be formed with respect to one or more aspects of a card  52 . The separation device  200  can be configured to use the graphics and/or images independently and/or in conjunction with other markings  74  to guide a singulation process, as discussed below. 
     In some embodiments, the locating device  100  is configured to generate a mapping file or other computer readable file indicative of a position of each card  52  within the laminate sheet  50 . The mapping file can be provided to the separation device  200  to direct a singulation process, as discussed in greater detail below. The mapping file can include information identifying and/or corresponding to the location of each card  52  within a laminate sheet  50 , such as, for example, spatial information (e.g., length, height, distance, spacing, etc.) of one or more cards  52  with respect to one or more reference marks formed on the laminate sheet  50  and/or edges of the laminate sheet  50 , dimensional information of one or more cards  52 , modification information (e.g., for adjusting relative positions of one or more cards  52  within a sheet template), and/or any other suitable information for calculating and/or determining a position of one or more cards  52  within a laminate sheet  50 . It will be appreciated that any suitable digital file can be generated by the locating device  100  for use by the separation device  200 . In some embodiments, the mapping file may include information regarding material density, material locations, material layers, and/or other material information to facilitate in tool selection during card singulation, which is discussed in greater detail below. 
     In one embodiment, the locating device  100  performs a physical modification of the laminate sheet  50  to assist the separation device  200  in identifying the locations of the cards  52  and/or singulating the cards  52 . For example, in some embodiments, after identifying the location of a core layer  54  within the laminate sheet  50 , the locating device  100  forms one or more physical modifications of the laminate sheet  50  at predetermined locations with respect to identified core layer  54 . For example, one or more physical modifications may be formed at a predetermined distance from one or more corners of a core layer  54 . Physical modifications may be formed with respect to each core layer  54  and/or a selected subset of the identified core layers  54 . The physical modifications may include, but are not limited to, holes, etchings, channels, punches, etc. formed in and/or through the laminate sheet  50 . In some embodiments, the physical modifications are used by the separation device  200  to identify the location of the cards  52 . In addition, in some embodiments, the physical modifications (such as drilled holes) serve as a point of introduction of a singulation instrument (such as a bit) of the separation device  200  to the laminate sheet  50 , as discussed in greater detail below. In some embodiments, each of the laminate sheets  50  is transferred from the locating device  100  to the separation device  200 . Although locating device  100  and separation device  200  are shown as separate aspects in  FIG.  9   , it will be appreciated that the card manufacturing system  2  can be combined into a single device, in accordance with some embodiments and as further described herein. 
     The separation device  200  is configured to receive each of the laminate sheets  50  and separate each of the plurality of cards  52  from the laminate sheet  50 . In some embodiments, the separation device  200  includes an imaging device configured to detect and/or otherwise image markings  74  and/or physical modifications formed by the locating device  100  on the laminate sheet  50 . The imaging device can include a visible spectrum imaging device and/or a non-visible spectrum imaging device. In some embodiments, the markings  74  include reactive materials and the imaging device of the separation device  200  includes a light source configured to apply a predetermined wavelength to the reactive markings. Although specific embodiments are discussed herein, it will be appreciated that the imaging device of the separation device  200  can be any suitable imaging modality configured to detect the markings generated by the locating device  100 . In some embodiments, the separation device  200  is configured to perform card separation (or singulation) based on the markings  74  and/or physical modifications formed on the laminate sheet  50  and/or a mapping file generated by the locating device  100 . 
     The separation device  200  includes a singulation mechanism configured to remove material from the laminate sheet  50 . The singulation mechanism is configured to remove surrounding material from each of the plurality of cards  52  formed in the laminate sheet  50 . In some embodiments, the separation device  200  includes a plurality of singulation mechanisms configured to remove multiple cards  52  from the laminate sheet  50  simultaneously. In some embodiments, the singulation mechanism can include any suitable singulation mechanism, such as milling instrument including a rotating bit, a cutting edge, etc., a vertical milling machine and/or a horizontal milling machine, a laser cutter, water jet, ultrasonic wire cutter, and/or any other suitable singulation mechanism. The separation device  200  separates the plurality of cards  52  from the laminate sheet  50 . After removal of the cards  52 , the edges of each of the cards  52  can be finished to clean and/or round the edges. The finishing of the edges can include buffing, polishing, grinding, sanding, etc. Finishing may be performed by the separation device  200  and/or by a separate finishing device (not shown). 
     In some embodiments, the separation device  200  is configured to remove a portion of the core layer  54  during separation. In such embodiments, a core layer  54  is initially over-sized and/or larger than the final desired card  52  dimensions. By removing a portion of the core layer  54 , the edges of the core layer  54  are exposed after singulation of the card  52 . Additionally, by removing a portion of the core layer  54  during the singulation process, the surface finish of the edges of the core layer  54  can be controlled during the singulation process by selecting the geometry of a singulation instrument (or singulation mechanism) as well as parameters such as rotation speed (e.g., of milling instrument), the feed rate, etc. During separation, the singulation instrument may remove a minimal amount of material from each core layer  54 . As a result, the singulation instrument is predominantly removing filler materials, such as PVC and EVA, which are generally softer than the core layers  54  and relatively easy to machine. The minimal amount of metal which is removed ensures that heat build-up is minimized and tool life of the singulation instrument/mechanism is maximized. In one embodiment, during singulation, less than 0.010″ is removed from each edge of each core layer. In another embodiment, less than 0.005″ is removed from each edge of each core layer. Although specific embodiments are discussed herein, it will be appreciated that the singulation mechanism can be configured to remove any amount of filler and/or core material from a card  52  during a singulation process. 
     In one embodiment, frame  65  is configured such that the space between each core layer is equal to, or just larger than, the cutting width of the milling instrument. As a result, only a single pass of the milling instrument is required to remove all of the material between adjacent core layers. For example, in some embodiments, the distance between adjacent core layers  54  may be substantially equal to a diameter of a singulation instrument. In other embodiments, the distance between adjacent core layers  54  may be substantially equal to a diameter of the singulation instrument minus a predetermined core layer removal amount. For example, in embodiments configured to remove 0.005″ of core material from each edge of a core layer  54 , the spacing between each core layer  54  may be equal to the diameter of the singulation instrument minus 0.01″ to allow removal of the desired 0.005″ of core layer  54  from each card  52  simultaneously. 
     In some embodiments, the separation device  200  is a computer-controlled separation device, such as a CNC (computer numeric controlled) machine. The separation device  200  is configured to automatically locate each of the plurality of cards  52  within a laminate sheet  50  based on the markings  74  formed by the locating device  100  and/or a mapping file generated by the locating device  100 . In some embodiments, after identifying a marking  74  corresponding to a card  52  and/or locating a card  52  based on a mapping file, the separation device  200  automatically removes the surrounding material from the perimeter of the card  52  to release the card  52  from the laminate sheet  50 . The markings  74  and/or the mapping file provide a guide for the automated separation device  200 . The edges of the cards  52  are finished during the removal process. In some embodiments, the edges of the processed cards  52   a  include a molecular edge (or bond) such that the plurality of layers comprising each individual card  52   a  are not separable. After singulating (i.e., removing) each of the cards  52   a  from the laminate sheet  50 , the remaining filler material can be discarded and the cards  52   a  provided for further processing and/or distribution. 
     In some embodiments, the separation device  200  includes separation mechanisms and/or instruments configured to be automatically interchanged during a card removal/singulation process. For example, in various embodiments, the separation mechanism can include a milling instrument having a plurality of interchangeable milling bits. One or more of the milling bits can be selected by the separation device  200  for initial removal, fine removal, finishing, and/or other processing of each of the cards  52  during card removal. In some embodiments, the separation device  200  may include multiple singulation mechanisms, such as a water jet, laser cutter, milling instrument, etc., that may be selectively applied to the laminate sheet  50  during card separation. For example, in some embodiments, the separation device  200  includes a first singulation mechanism configured to perform an initial singulation of each of the cards  52  during card removal and a second singulation mechanism configured to perform polishing and/or finishing of each of the cards  52 . The first singulation mechanism may be configured to perform a rough or incomplete cut and the second singulation mechanism may be configured to perform a finishing or polishing cut to form a predetermined edge profile. In some embodiments, the first singulation mechanism includes a first milling bit and the second singulation mechanism includes a second milling bit, although it will be appreciated that the first singulation mechanism and/or the second singulation mechanism can include any suitable singulation mechanisms. 
     The card manufacturing system  2  is configured to process laminate sheets  50  containing cards of various widths, heights, and/or thicknesses. For example, in some embodiments, card manufacturing system  2  is configured to process laminate sheets  50  containing cards having a thickness of up to about 40 mils, although it will be appreciated that the card manufacturing system  2  can be configured to process cards having any suitable thickness. The card manufacturing system  2  is further configured to process laminate sheets  50  including cards  52  having variable widths and/or heights. In some embodiments, the locating device  100  is configured to image each card  52  and provide markings  74  and/or a mapping file corresponding to the position of each card. In some embodiments, the markings further correspond to the width and/or height of the individual cards. The separation device  200  is guided by the markings and/or mapping file and can process cards  52  having various widths and heights without needing to retool and/or reconfigure the separation device  200 . In some embodiments, a reference location is identified by a marking  74   b  and the separation device  200  operates based on calculated and/or known positions of the core layers  54  within the laminate sheet  50  with respect to the reference location. The calculations and/or known positions may be included in, for example, a mapping file generated by the locating device  100 . 
     In some embodiments, the separation device  200  is configured to generate additional and/or alternative processing and/or milling in one or more cards  52  on the laminate sheet  50 . For example, in some embodiments, the separation device  200  is configured to perform aesthetic milling to generate one or more milled images, features, signatures and/or other aesthetic elements on one or more cards  52 . The aesthetic milling can occur prior to, simultaneously with, and/or after removal of the surrounding material from the periphery of the card  52 . In some embodiments, markings  74  and/or a mapping file generated during the inspection process are used to form aesthetic elements during the separation process. In some embodiments, the separation device  200  is configured to locate the aesthetic elements based on original markings and/or additional imaging systems formed integrally with the separation device  200 . 
     In some embodiments, the separation device  200  is configured to remove a portion of material from within a periphery of one or more of the cards  52  during the separation process. For example, in some embodiments, the separation device  200  is configured to remove a portion of material from within a card  52  for positioning one or more additional materials, elements, and/or other devices within the card  52 . For example, in some embodiments, the separation device  200  is configured to generate channels for EMV chips. As another example, in some embodiments, the separation device  200  is configured to remove a portion of material to allow positioning of an additional material/object within the periphery of the card  52 . In some embodiments, the separation device  200  is configured to form one or more channels, cutouts, and/or other discontinuities in a card  52 . 
       FIGS.  11 - 17    show one embodiment of a card manufacturing system  2  in which the locating device  100  and the separation device  200  share a common worktable  202 . The card manufacturing system  2  includes a worktable  202 , one or more transport arms  204  mounted on a transport rail  206 , an x-ray source  208 , an x-ray receiver  210 , and a spindle  212  mounted to a gantry  214 . A loading station  300  is positioned at a first end of the card manufacturing system  2  and an unload station  400  is positioned at a second end of the card manufacturing system  2 . In some embodiments, a discard station  500  is positioned near the second end for collecting discarded portions of the laminate sheet  50 , as will be described further herein. 
     The transport arm  204  is configured to travel horizontally along the transport rail  206  and/or to vertically raise and lower relative to the transport rail  206 . The transport arm  204  is configured to move a laminate sheet  50  from the loading station  300  to the worktable  202 . Subsequently, after separation of the cards  52 , the transport arm  204  is configured to move the singulated cards from the worktable  202  to the unload station  400 . In the illustrated embodiment, the transport arm  204  also moves the remainder of the excess portions of the laminate sheet  50  to the discard station  500 . The transport arm  204  may use any suitable system to engage the laminate sheet  50  and/or cards  52  during transportation, such as, for example, a vacuum system. Although embodiments are discussed herein including a single transport arm  204 , it will be appreciated that the card manufacturing system  2  can include any number of transport arms  204 , for example, one, two, three, or more transport arms. 
     In the illustrated embodiment, as shown best in  FIG.  15   , the transport arm  204  includes a plurality of vacuum cups including card vacuum cups  216  and frame vacuum cups  218 . The card vacuum cups  216  are positioned to generally correspond to an area of the cards  52  within the laminate sheet  50  when the transport arm  204  is aligned with each laminate sheet  50 . The frame vacuum cups  218  are positioned such that they generally align with the laminate sheet  50  between or around the cards  52  when the transport arm  204  is aligned with the laminate sheet  50 . The card vacuum cups  216  and frame vacuum cups  218  can be connected to a common vacuum source and/or one or more of the card reference cups  216  can be operatively connected to a first vacuum source  220  and one or more the frame vacuum cups  218  can be operatively connected to a second vacuum source  222  (as shown in  FIG.  9   ). In the illustrated embodiment, the card vacuum cups  216  may be of a larger size (e.g. diameter) than the frame vacuum cups  218 , however, any relationship in size is contemplated within the scope of this disclosure. For example, the card vacuum cups  216  may be larger than, smaller than, or equal to the frame vacuum cups  218 . The vacuum cups  216 ,  218  may include a material configured to prevent marking, scratching, and/or other defacing of the cards  52 . For example, in some embodiments, one or more of the vacuum cups  216 ,  218  may include a silicon, rubber, and/or other material configured to prevent marking of the cards  52 . Although embodiments are discussed herein including a vacuum coupling system, it will be appreciated that the transport arm  204  can use any suitable mechanism for moving a laminate sheet  50  and/or singulated cards  52  into and/or out of various elements of the card manufacturing system  2 . For example, in various embodiments, the card manufacturing system  2  may use belts, rollers, electromagnets, and/or any other suitable transport systems. 
     To begin a cycle of the card manufacturing system  2 , the transport arm  204  is positioned above the loading station  300 . The transport arm  204  is lowered such that one or more of the vacuum cups  216 ,  218  contacts the top laminate sheet  50  on the loading station  300 , as shown in  FIG.  12   . A vacuum is initiated to secure the vacuum cups  216 ,  218  to the laminate sheet  50 . For example, a vacuum may be applied to the card vacuum cups  216  and/or the frame vacuum cups  218  to couple the laminate sheet  50  to the transport arm  204 . The transport arm  204  is then raised to lift the laminate sheet  50  from the loading station  300 . The transport arm  204  may be moved in a predetermined fashion, such as being repeatedly raised and lowered, to ensure that only one laminate sheet  50  is secured. The transport arm  204  then translates along transport rail  206  such that the laminate sheet  50  is aligned over the worktable  202 . The transport arm  204  is then lowered to position the laminate sheet  50  on the worktable  202 . The vacuum in transport arm  204  may then be reduced or eliminated to release the laminate sheet  50 . Although embodiments are discussed herein having a raised transport rail  206 , it will be appreciated that the transport rail  206  can be positioned at any suitable location to allow the transport arm  204  to transverse over and/or with respect to the worktable  202 . 
     In some embodiments, the worktable  202  is configured to fix the laminate sheet  50  in place. For example, in some embodiments, the worktable  202  includes a vacuum fixture  203 . The vacuum fixture may have one or more vacuum channels  203   a  positioned such that at least one vacuum channel  203   a  is generally located under each card  52  of the laminate sheet  50  when the laminate sheet  50  is positioned on the worktable  202 . In one embodiment, as shown in  FIG.  13   , the vacuum fixture includes four circular vacuum channels  203   a  each configured to be generally positioned under card  52  in a laminate sheet  50 , although it will be appreciated that any number of vacuum channels can be used. For example, a single rectangular vacuum channel can be configured to be positioned around the periphery of each card  52 . In some embodiments, the vacuum fixture includes a plurality of vacuum holes positioned such that the vacuum holes are generally located under the portion of the laminate sheet  50  without any cards  52  (e.g., the “frame” of the laminate sheet  50 ). The vacuum fixture ensures that the laminate sheet  50  is securely held in place during imaging and separation. For example, the plurality of vacuum holes apply a vacuum force to the frame of the laminate sheet  50  to further stabilize the frame, reduce vibration and chatter during card singulation, and improve the separation results and/or smoothness of a finished edge of each card. The vacuum fixture may include a vacuum foot (or contact foot) formed of a material configured to protect the cards  52 . Although embodiments are discussed herein including a vacuum fixture integrated with the worktable  202 , it will be appreciated that additional and/or alternative coupling mechanisms may be employed to maintain a position of the laminate sheet  50  with respect to the worktable  202 . For example, in various embodiments, the worktable  202  may include one or more clamps, fixtures and/or other coupling mechanism configured to maintain the laminate sheet  50  in a fixed position with respect to the worktable  202 . 
     The worktable  202  may be movable along one or more axes. For example, the worktable may be movable along a y-axis such that in an extended position the worktable  202  is generally positioned beneath the transport rail  206 . From this extended position, the worktable  202  may translate along the y-axis to a retracted position for further processing of the laminate sheet  50 . In other embodiments, the worktable  202  may translate on an x-axis to transfer a laminate sheet  50  from the locating device  100  to the separation device  200 . 
     After the cards are singulated, for example, the worktable  202  returns to the extended position. The transport arm  204  is again positioned over the worktable  202  and lowered to engage the cards  52  and remaining portion of the surrounding material. In some embodiments, the card vacuum cups  216  engage the singulated cards  52  and the frame vacuum cups  218  engage the remainder of the laminate sheet  50 . The transport arm  204  is then raised, as shown in  FIG.  14   , and translated to a position above the discard station  500 . At this location, the vacuum in the frame vacuum cups  218  is reduced or terminated. As a result, the remaining portion of the laminate sheet  50  is released and allowed to fall into the discard station  500 , as shown in  FIG.  16   . The transport arm  204  is then positioned above the unload station  400 , as shown in  FIG.  17   . In this position, the vacuum in the card vacuum cups  216  is reduced or terminated. As a result, each of the cards  52  is able to fall into the unload station  400 . The unload station  400  can include sleeves  402  into which the cards fall, thereby separating the cards into individual stacks. This may allow for easy handling and sorting of the cards at later stages of production. 
     In at least one embodiment, the card manufacturing system  2  includes two transport arms  204  (shown in  FIG.  9   ), each having a set of card vacuum cups  216  and a set of frame vacuum cups  218 . The first transport arm transports sheets from the loading station  300  to the worktable  202 . The second transport arm transports the separated cards and remaining portions of the laminate sheets  50  to the unloading station  400  and discard station  500 , respectively. In this way, the transport arms  204  can operate simultaneously, thereby increasing the speed and efficiency with which the card manufacturing system  2  operates. 
     Each of the vacuum cups  216 ,  218  can be mounted to a common platform  224  which moves the vacuum cups  216 ,  218  vertically and/or horizontally in unison. In such an embodiment, the platform  224  may be mounted to one or more pneumatic or hydraulic cylinders  204   a  which allow vertical movement relative to the transport rail  206 . Alternatively, the platform can be mounted to one or more drive screws operated by an electric motor, such as an AC motor, a DC motor, or a stepper motor. It will be appreciated that any suitable mechanism can be configured to move the common platform  224  on one or more axes. 
     Alternatively, the vacuum cups  216 ,  218  may be configured to operate independently. In such an embodiment, each vacuum cup  216 ,  218 , and/or a group of vacuum cups, can be coupled to a pneumatic or hydraulic cylinder or a motor-driven drive screw. Such an embodiment may be used in cases where the number of cards on a sheet varies, thereby allowing flexibility in the card manufacturing system  2 . 
     In some embodiments, each of the loading station  300 , unloading station  400 , and/or discard station  500  can be provided with wheels or other means for moving the stations. This allows an operator to easily place or remove the stations  300 ,  400 ,  500  when they are empty or full. 
     A method  250  of singulating a plurality of cards  52  is shown in  FIG.  18   . The method  250  may be implemented by a card manufacturing system  2  as discussed and described above. At step  252 , at least one laminated sheet  50  is provided to a loading station  300  positioned adjacent to and/or at a predetermined position with respect to a locating device  100  of a card manufacturing system  2 . In some embodiments, the at least one laminated sheet  50  may be provided to the loading station  300  at a location remote from the locating device  100  and delivered to the locating device  100  in conjunction with the loading station  300 . In other embodiments, the laminate sheet  50  may be provided to a loading station  300  permanently and/or temporarily positioned adjacent to the locating device  100  prior to delivery of the laminate sheet  50 . 
     At optional step  253 , an axis calibration and/or system verification may be performed. In some embodiments, the locating device  100 , separation device  200 , transport arms  204 , and/or any other suitable element may use one or more known or fixed locations to calibrate one or more elements to a known-zero location. For example, in some embodiments, the locating device  100  may be configured to take an initial image without a laminate sheet  50  to confirm operation and positioning of an imaging element prior to imaging a laminate sheet  50 . Similarly, the separation device  200  may position a singulation tool at a known location corresponding to a “zero” location of the singulation tool. It will be appreciated that any suitable calibration and/or system verification may be performed prior to processing one or more laminate sheets. 
     At step  254 , the laminate sheet  50  is transferred from the loading station  300  to a predetermined position within the locating device  100 . For example, in some embodiments, the laminate sheet  50  is transferred to a predetermined position on a worktable  202  formed integrally with and/or positioned at a locating device  100 . The laminate sheet  50  may be transferred using any suitable mechanism. For example, in some embodiments, the laminate sheet  50  is transferred by a transport arm  204  including one or more vacuum cups  216 ,  218  configured to apply vacuum suction to the laminate sheet  50  to couple the laminate sheet  50  to the transport arm  204 . In other embodiments, the laminate sheet  50  may be transferred by a transport arm  204  including any suitable coupling mechanism such as a vacuum coupling mechanism, a clamping mechanism, a grasping mechanism. In still other embodiments, the laminate sheet  50  may be transferred by a transfer mechanism such as a conveyor belt, pusher, and/or any other suitable mechanism. In an exemplary embodiment, the laminate sheet  50  is positioned at a predetermined position on the worktable  202 . 
     At step  256 , the laminate sheet  50  is coupled to the worktable  202  (or other surface of the locating device  100 ). The laminate sheet  50  can be coupled to the worktable  202  by any suitable mechanism, such as a vacuum system  203  formed integrally with the worktable  202 . The vacuum system  203  can include a plurality of vacuum channels  203   a  extending within the worktable  202  and positioned below a portion of the laminate sheet  50 . The vacuum system  203  is configured to apply a vacuum through the plurality of vacuum channels  203   a  to couple the laminate sheet  50  to the worktable  202 . In other embodiments, a mechanical clamping mechanism and/or other coupling device may be used to couple the laminate sheet  50  to the worktable  202 . In some embodiments, the vacuum system  203  includes a foot  205  configured to contact the laminate sheet  50  and/or the cards  52 . The vacuum foot  205  can include any suitable material, such as a bristle brush, felt, and/or any other suitable material. 
     At step  258 , the laminate sheet  50  is imaged to determine the position of the cards  52  within the laminate sheet  50 . Step  258  can be performed by the locating device  100  described herein. In some embodiments, as discussed above, the imaging is performed in a non-visible spectrum, such as x-ray imaging, ultrasound, infrared, electromagnetic, microwave, etc. The locating device  100  is configured to identify the position of each of the plurality of cards  52  within the laminate sheet  50 . For example, the locating device  100  may be configured to identify the absolute position of each of the plurality of cards  52  within the laminate sheet  50  and/or may be configured to identify a relative position of each of the plurality of cards  52  with respect to at least one reference point of the laminate sheet  50 . 
     At optional step  260 , a mapping file containing mapping information for the laminate sheet  50  is generated. The mapping file can include a digital file identifying a position (either absolute or relative) of each of the plurality of cards  52  within the laminate sheet  50 . Alternatively, the mapping file may include a reference point, one or more vectors for identifying an edge or other reference for each of the plurality of cards  52 , and dimension information for each of the plurality of cards  52 . Although specific embodiments are discussed herein, it will be appreciated that the mapping file can include any suitable format for identifying the position of each of the plurality of cards  52  within the laminate sheet  50  and directing a separation mechanism of the separation device  200  to singulate each card  52 . 
     At optional step  262 , the locating device  100  forms one or more markings and/or physical alterations on the laminate sheet  50 . The markings  74  and/or physical alterations may correspond to a reference position and/or a position of at least one card. The markings  74  can include visible markings (such as printed markings formed by a visible ink and/or etching), non-visible markings (such as printed markings formed by non-visible spectrum ink), and/or reactive markings (such as printed markings formed by ultraviolet or other light reactive ink). The physical alterations can include, but are not limited to, holes, etching, trenches, channels, etc. formed in and/or through the laminate sheet  50 . The markings  74  and/or the physical alterations may be used, either alone or in combination with a mapping file, by a separation device  200  for positioning and/or guiding a singulation instrument. In some embodiments, the markings  74  and/or the mapping file may include information regarding the laminate sheet  50 , such as, for example, the number of cards  52  included in the laminate sheet  50 , the size of various cards  52  contained within the laminate sheet  50 , and/or any other suitable information regarding the laminate sheet  50  and/or the cards  52 . 
     At optional step  263 , the locating device  100  is configured to verify placement, orientation, and/or other features of graphics formed on the individual cards  52  within the laminate sheet  50 . In some embodiments, the locating device  100  includes an imaging modality configured to image the laminate sheet  50  in a first wavelength, such as a visual spectrum imaging modality, and an imaging modality configured to image the laminate sheet  50  in a second wavelength, such as an x-ray or other non-visible imaging modality. The locating device  100  is configured to overlay or otherwise combine imaging data generated from the first imaging modality with imaging data generated by the second imaging modality to verify placement, orientation, and/or configuration of one or more graphics. For example, in some embodiments, the locating device  100  is configured to determine if a graphic is positioned substantially over a card  52  within the laminate sheet and/or whether a portion of the graphic is correctly positioned with respect to some element within the card  52 , such as, for example, a discontinuity or cavity. In some embodiments, the locating device  100  rejects the laminate sheet  50  if the cards  52  and graphics are not aligned within a predetermined margin of error. 
     At step  264 , the laminate sheet  50  is transferred from the locating device  100  to the separation device  200 . The laminate sheet  50  may be transferred by any suitable transfer mechanism, such as, for example, a transfer arm  204  configured to be releasably coupled to the laminate sheet  50 . The transfer arm  204  may be the same transfer arm  204  used to transfer the laminate sheet  50  from the loading station  300  and/or a different transfer arm  204 . In other embodiments, the transfer mechanism may include a conveyor belt, push mechanism, grasping mechanism, and/or any other suitable transfer mechanism. In some embodiments, a worktable  202  is configured to transfer the laminate sheet  50  from the locating device  100  (or a portion of a shared housing including the locating device  100 ) to the separation device  200  (or a portion of a shared housing including the separation device  200 ). The worktable  202  may be configured to transfer the laminate sheet  50  in a direction transvers to the direction of travel of the transfer arm  204 . 
     At step  266 , the separation device  200  receives position information for one or more cards  52  and determines the location of one or more cards  52  within the laminate sheet  50 . For example, in embodiments in which the locating device  100  generates a mapping file, the separation device  200  is configured to receive the mapping file into memory and identify a position of one or more cards  52  within the laminate sheet  50 . As another example, in some embodiments, the separation device  200  is configured to use markings  74  placed on the laminate sheet  50  by the locating device  100  to identify the position of each of the plurality of cards  52  within the laminate sheet  50 . For example, in various embodiments, the separation device  200  includes an imaging device configured to image and/or identify the markings  74  formed on the laminate sheet  50 . The imaging modality may be configured to image the markings  74  in a visible and/or non-visible spectrum. In another embodiment, the separation device  200  is configured to identify one or more surface markings and/or holes formed in the laminate sheet  50  by the locating device  100 . 
     At optional step  267 , the separation device  200  selects a singulation instrument or tool from a plurality of singulation instruments or tools. For example, in some embodiments, the imaging device  100  is configured to generate material information in addition to position information and/or additional information generated during steps  258  and  260 . The material information may include, but is not limited to, material density, material type, material hardness, layering information, and/or any other suitable material information. The separation device  200  is configured to select a singulation tool based on the material information and/or predetermined tool designations. For example, in some embodiments, the separation device  200  is configured to select a first singulation tool or instrument, such as a bit having a first profile and a first size, for a first material, such as PET, and a second singulation tool or instrument, such as a bit having a second profile and/or a second size, for a second material. In some embodiments, the separation device  200  is configured to perform optional step  267  multiple times to select different tools for different portions of the laminate sheet  50  containing different materials. In various embodiments, the singulation tool may include a profile such as a tapered profile, an hourglass profile, a cylindrical profile, a fluted profile, and/or any other suitable profile or combination thereof. 
     At step  268 , each of the plurality of cards is singulated. The cards  52  may be singulated by a separation device  200  as discussed above. For example, in some embodiments, a separation device  200  includes a singulation instrument that is guided and/or positioned based on the plurality of card  52  positions identified by the locating device  100 . The singulation instrument may be guided optically (e.g., using markings formed on the laminate sheet  50 ) and/or digitally (e.g., using a mapping file previously generated for the laminate sheet  50 ). In some embodiments, the singulation instrument includes a plurality of bits or cutting instruments configured to remove filler material and/or material to separate each card  52  from the laminate sheet  50 . The separation device  200  may select a bit and/or cutting instrument based on information included in the mapping file, for example, information regarding the material of the core layers  54  and/or the filler material, the position of each card  52  within the laminate sheet  50 , the dimensions of each card, and/or any other suitable information. 
     At optional step  269 , a tool life monitoring process is performed to measure the remaining and/or used tool life of the singulation instrument used at step  268 . In some embodiments, the tool life monitoring process measures one or more dimensions of a singulation instrument to determine the remaining life on the singulation instrument. For example, in some embodiments, a diameter of the singulation instrument may be measured to determine the remaining tool life of the singulation instrument. In other embodiments, the separation device  200  is configured to maintain a run-time or card-count related to the total amount of time and/or the total number of cards removed from laminate sheets  50 . Each singulation instrument may have a predetermine run-time life and/or predetermined material removal life. In some embodiments, the tool life may be adjusted based on material information received from the location device  100 . 
     At optional step  270 , additional processing and/or milling of one or more cards  52  is performed to form cavities, spacing, etchings, and/or other physical features on the card  52 . In some embodiments, the singulation instrument and/or an additional tool (such as an additional and/or alternative milling bit) may be used to further finish the edges and/or remove additional material from one or more of the cards  52 . The additional processing and/or milling can be performed prior to, during, and/or after singulation of the cards  52 . For example, the edges of each card  52  can be ground, sanded, polished, or otherwise finished. This finishing process can provide desirable surface finishes on the edge of the card. 
     At step  272 , the plurality of cards  52  are transferred from the separation device  200  to an unload station  400 . For example, in some embodiments, each of the plurality of cards  52  interact with a vacuum cup  216  formed on a transfer arm  204 . A predetermined vacuum level is applied to each of the vacuum cups  216  to couple the cards  52  to the transfer arm  204 . The transfer arm  204  is moved from the separation device  200  to a position corresponding to the unload station  400 . After positioning the transfer arm  204 , the vacuum pressure is reduced or eliminated, and the cards  52  are separated from the vacuum cups  216 . In some embodiments, the cards  52  are deposited into racks or other containers. 
     At step  274 , the remainder of the laminate sheet  50  is transferred from the separation device  200  to a discard station  500 . For example, in some embodiments, the remainder of the laminate sheet  50  interacts with at least one frame vacuum cup  218  formed on a transfer arm  204 . A predetermined vacuum level is applied to each of the vacuum cups  218  to couple the remainder of the laminate sheet  50  to the transfer arm  204 . The transfer arm  204  is moved from the separation device  200  to a position corresponding to the discard station  500 . After positioning the transfer arm  204 , the vacuum pressure is reduced or eliminated, and the remainder of the laminate sheet  50  is separated from the vacuum cups  218 . At step  276 , the plurality of cards  52  may be transferred from the unload station  400  for further processing and/or programming. 
     In some embodiments, the card manufacturing system  2  includes one or more circuit elements configured for controlling, monitoring, and/or otherwise operating the elements of the card manufacturing system  2 . For example, in various embodiments, one or more elements of the card manufacturing system  2  may include one or more processors configured to be programmed to operate one or more predetermined functions and/or processes of the card manufacturing system  2 . 
       FIG.  19    illustrates a block diagram of a card manufacturing system  2   a  illustrating various signal connections therein, in accordance with some embodiments. In the illustrated embodiment, the card manufacturing system  2   a  includes a processor  602  and a non-volatile memory module  604  in signal communication with each of the locating device  100 , the separation device  200 , and the transfer arm  204 . In some embodiments, the processor  602  is configured to implement one or more processes and/or methods, such as, for example, the method  250  discussed above. 
     In some embodiments, the processor  602  is in signal communication with one more elements of the locating device  100   a . For example, in the illustrated embodiment, the processor  602  is in signal communication with an imaging modality  606  formed integrally with the locating device  100   a . As discussed above, the imaging modality  606  is configured to generate an image of the laminate sheet  50 , for example, in a non-visible spectrum. The imaging modality  606  transmits the image data to the processor  602 . 
     The processor is configured to receive the imaging data from the imaging modality  606  and generate a mapping file  608  of the laminate sheet  50 . The mapping file  608  may be stored in the non-volatile memory module  604 . In some embodiments, the processor  602  is configured to utilize the mapping file  608  (and/or the imaging data received from the imaging modality  606 ) for directing one or more additional operations of the locating device  100 . For example, in some embodiments, the processor  602  is in signal communication with a marking instrument  610  configured to generate at least one marking  74  on the laminate sheet  50 . As discussed above, the marking instrument  610  can be configured to generate any suitable visible, non-visible, and/or reactive marking on the laminate sheet  50 . 
     In some embodiments, the processor  602  is in signal communication with the transfer arm  204 . The processor  602  is configured to operate the transfer arm  204  to transfer the laminate sheet  50  from a first station to a second station in response to one or more trigger conditions. For example, in some embodiments, in response an initialization or begin condition, the processor  602  operates the transfer arm  204  to transfer a laminate sheet  50  from a loading station  300  to the locating device  100   a . As another example, in some embodiments, in response to generating a mapping file  608 , the processor  602  operates the transfer arm  204  to transfer a laminate sheet  50  from the location device  100   a  to the separation device  200   a . Although embodiments are discussed herein including a single transfer arm  204  operated by the processor  602 , it will be appreciated that any number of transfer arms  204  can be controlled by the processor  602  to move multiple laminate sheets  50  in parallel and/or series. 
     In some embodiments, the processor  602  is configured to provide the mapping file  608  to the separation device  200   a  and/or to calculate one or more inputs for the separation device  200   a  based on the mapping file  608 . For example, as discussed above, the separation device  200   a  is configured to singulate one or more cards contained within the laminate sheet  50 . The separation device  200   a  is configured to utilize the image data contained in the mapping file  608  to guide a singulation tool when singulating one or more cards, as discussed above. 
     In various embodiments, the non-volatile memory module  604  is configured to store a plurality of programs  620   a - 620   c . Each of the plurality of programs  620   a - 620   c  is configured to calibrate the location device  100  and/or the separation device  200  for a laminate sheet  50  having one or more selected parameters, such as, for example, a predetermined core material, filler material, card dimension, card number, laminate sheet dimensions, and/or any other selected parameters. For example, in various embodiments, the plurality of programs  620   a - 620   c  include programs specific to one or more core materials, such as, for example, metal core materials, high density core materials, and/or other core materials. In other embodiments, the plurality of programs  620   a - 620   c  includes one or more programs configured to account for material inlays, aesthetic and/or functional cuts formed in one or more cards, and/or any other suitable card features. 
     Rectangular shaped information carrying cards or smart cards in this disclosure are for illustration only. The disclosed structure and process of making also apply to any information carrying card or part of any shapes and any size. Examples of these parts include but are not limited to rectangular sheets, circular sheets, strips, rods, and rings. The size includes but is not limited to any size following: ISO/IEC 7810 standard. 
     Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.