Patent Description:
The term "card" or "cards" as used herein, is intended to include a large variety of documents and instruments such as financial cards, identification (including a National ID or Driver's License) cards, electronic passport pages, gift cards, documents of any type, including documents for holding permanent and long lasting records such as medical records or security cards, or plastic cards used for promotion of a product or organization. Also included are smart cards which may be of the contact type or contactless and dual interface financial transaction cards and documents.

<CIT> discloses a transaction card having a sandwich structure, comprising a core layer on which information can be printed and comprising a buffer layer.

It is an object of this invention to produce cards whose planar surfaces have a selected appearance and texture and to a method for making these cards which can be controlled to produce desired visual and tactile effects.

The invention pertains to a multilayered card as outlined in claim <NUM> and to a method of forming said card as outlined in claim <NUM>. Embodiments of the invention are outlined in the dependent claims.

That is, embodiments of the invention include a card assembly, or subassembly, having an outer layer which is a laser reactive copolymer. The copolymer portion of the laser reactive copolymer layer ensures that when the layer is embossed (or debossed) with a selected pattern (image) at a predetermined temperature (above the glass transition temperature, Tg, of the copolymer and below its melting temperature, Tm) it becomes thermoset, rather than being thermoplastic, and its external shape cannot be changed from the embossed form to which it was set at the predetermined temperature, without destroying the pattern (image). The laser reactive portion of the copolymer layer enables virtually any desired information or design to be laser engraved on or within the layer and to also alter the color of the layer. The resultant embossed pattern is found to be scratch resistant and to mask scratches due to the optical light reflectivity of the embossed pattern.

A card assembly (or subassembly) embodying the invention includes a plurality of layers forming what may be termed sandwich. According to the invention, the sandwich includes an amorphous laser reactive copolymer outer layer (e.g., the front of the card) attached to one side of a thermoplastic layer whose other side is attached to a core layer which in turn is attached to a laser reactive layer (e.g., the back of the card). The copolymer layer of cards embodying the invention may be any polymer which can be embossed and thermally set to hold an embossed/debossed pattern. The copolymer may be an amorphous polyethylene terephthalate (APET) or any like thermoplastic polymer resin of the polyester family. The copolymer is stiffer than PVC and can be thermally set into the desired pattern. When set it exhibits and maintains a scratch resistant property. The thermoplastic layer may contain or support an integrated circuit chip. The core layer is a metal layer.

The sandwich undergoes a lamination and embossing (or debossing) process which calls for embossing the copolymer layer at a predetermined pressure and at a temperature between Tg and Tm. Embossing the copolymer layer at the selected temperature ensures that the pattern imparted to the copolymer layer cannot be readily changed from the embossed form to which it was set at the selected temperature.

Cards embodying the invention may be embossed by a type of embossment which may be referred to as "surface embossing". That is, only the outer layer (or layers) is subjected to imprinting. The embossing plate is made to allow for the absorption of excess material and there is no embossment beyond the outer layer.

In the making of cards embodying the invention, a laser may be applied to the laser reactive copolymer (e.g., APET) layer and/or to another laser reactive (e.g., PVC) layer before, or after, the lamination and embossing step. The laser engraving of these layers allows any information to be written on or within these layers and to also alter the color of these layers and an assembly or subassembly.

Note that in the discussion above and to follow reference is made to embossing. However, it should be understood that the invention is equally applicable to "debossing" which is merely the opposite of embossing. So that instead of raising an image it depresses it. Therefore, in the appended claims, the word embossing is to be construed to also include debossing.

According to of the invention, the core layer (also referred to herein as the substrate) is a metal layer with different plastic layers being formed above and below the metal core layer.

Embodiments of the invention may include laser reactive copolymer layers on the top and bottom surfaces (the two outer surfaces) of a card.

Still other embodiments of the invention may include laser reactive layers selected to provide a background color to the card and which can be treated with a laser to provide predetermined information or patterns.

Plastic layers below the embossed top layer may provide color to the metal core layer, printed images or text, hot stamped foils or images, and other means of imparting images known in the card manufacturing field.

One aspect of the invention is that it provides a unique solution for providing texture and color to metal cards. Another aspect of the invention is creating optical contrast on the card by creating areas of raised and lower materials, altering the way light reflects from the surface. Another aspect of the embossing is the ability to provide patterning on the surface of the card and changing the appearance of the card from glossy to matte.

in the accompanying drawings, which are not drawn to scale, like reference characters denote like components; and.

<FIG> shows a subassembly <NUM> which includes a thermoplastic layer <NUM> over which is located an adhesive layer <NUM> over which is located a metal layer <NUM> over which is located an adhesive layer <NUM> over which is formed a laser reactive film layer <NUM>. The thermoplastic layer <NUM>, also referred to as an inlay, is shown to include a chip module <NUM> (also denoted as an integrated circuit ,IC), a chip antenna <NUM> coupled to the chip and a booster antenna <NUM> as shown in greater detail in <FIG>. The chip <NUM> may be mounted on or within layer <NUM>. Layer <NUM> may be a PVC pigmented (colored) thermoplastic layer having a color selected to be imparted to the card. The adhesive layer <NUM> is selected to ensure adhesion of layer <NUM> to the underside of metal layer <NUM>, as shown in <FIG>. In <FIG>, the metal layer <NUM> is shown to be a "thick" metal layer (e.g., <NUM> (<NUM> inches)) and functions as the core layer (or substrate of the card). However the layer <NUM> may be much thinner (i.e., it may be a thin foil layer of vapor deposited metal of <NUM> (<NUM> angstroms) thickness) or it may even be thicker up to <NUM>,<NUM> (<NUM> inches). Alternatively, metal layer <NUM> may be replaced by a plastic layer which includes high density particles which simulate a metal layer. Still further, layer <NUM> may be a plastic core layer to produce an all plastic card.

The laser reactive film <NUM> is attached to the topside of metal layer <NUM>, as shown as in <FIG>. The layer <NUM> is typically made of polyvinylchloride (PVC) which is a material that is particularly well adapted to printing. Layer <NUM> is also made laser reactive to enable treatment by a laser to control imparting of information and certain color control. The laser reactive film <NUM> enables any selected information, pattern or design to be imparted to the laser reactive film <NUM> via a suitable laser device <NUM>. In the making of cards embodying the invention the laser reactive film <NUM> may be selected to have any desired, and/or suitable, color. The selected color will project this coloring to a viewer facing that side of the card. Subassemblies, such as subassembly <NUM>, may be subjected to further processing (e.g., the addition of other layers, lamination, etc.. ) to form cards having desired qualities and characteristics.

A laser reactive copolymer layer may be attached to the top and/or to the bottom of subassembly <NUM>. <FIG> shows that the subassembly <NUM> can be modified with the addition of a laser reactive copolymer layer 106b underlying layer <NUM> (in <FIG>) to form a sub assembly <NUM>. Actually, layer 106b is normally intended to be, and function as, the front of the card. Note also that a magnetic stripe <NUM> is typically attached to the back of the card (on top of layer <NUM> in <FIG>).

The introduction of the laser reactive copolymer layer 106b provides significant features. The laser reactive copolymer layer 106b is preferably an amorphous thermoplastic polyester plastic material such as polyethylene terephthalate (APET) or any like material. A significant aspect of this amorphous thermoplastic material is that certain of its properties change drastically as it is heated above its glass transition temperature, Tg, and below its melting point temperature, Tm. When heat is applied to the plastic material such that it is at a selected temperature, which exceeds its Tg and is less than its Tm, the plastic material starts to cross link or crystalize and enters a thermosetting state (rather than being a thermoplastic). As used herein and in the appended claims, this means that its external shape cannot be changed without irreversible destruction from the form it assumed when it reached the selected temperature. Thus, the copolymer layer 106b can be heated to a selected temperature within this temperature range (between Tg and Tm) to cause the material to enter a crystalline state and assume a (thermo)set condition.

The temperature dependent characteristic of the copolymer layer 106b ensures that when the layer 106b is embossed (or debossed) with a pattern at a predetermined temperature (above the glass transition temperature, Tg, of the copolymer and below its melting temperature, Tm) it becomes thermoset, rather than being thermoplastic, and its external shape (the embossed form) cannot be changed from the embossed form to which it was set at the predetermined temperature without destroying the embossed pattern. The resultant embossed pattern is found to be scratch resistant and to mask scratches due to optical light reflectivity of the embossed pattern. The copolymer (e.g., APET) selected for use in practicing the invention is stiffer than PVC and can be thermally set into the desired pattern. By way of example, a co-polyester manufactured by Eastman Chemical under the brand name Tritan was used to make some experimental cards.

Another significant aspect of layer 106b is that it is also laser reactive so it can be laser engraved to enable information to be introduced on or within the layer. In addition, the laser reactive property enables the color of the layer to be altered to shades of black or white dependent on laser settings. The laser reactive portion of the copolymer layer enables virtually any desired information or design to be laser engraved on or within the layer and to also alter the color of the layer. <FIG> shows that the laser reactive copolymer layer 106b and the laser reactive film <NUM> may be operated upon (treated) by a suitable laser device 120a and/or 120b to form any design or pattern so the layers 106b and <NUM> can contain any desired information. The laser reactive copolymer layer 106b (as well as layer 106a discussed below) includes silicon and carbon particles. Applicants discovered that by controlling the power and wavelength of the lasering device (e.g., 120a, 120b) directing their energy onto the laser reactive copolymer layers 106a and/or 106b the color of the layers could be controlled from their native state. The laser reactive copolymer films may be treated with the laser to turn their surface from their native color to black or the layers may also be turned white by changing the selected laser frequency and power settings. This color change can be produced as a gradient, by altering laser power and exposure time. By controlling the color and resultant contrast, a variety of desired images may be produced in the copolymer layers 106a, 106b. The final laser effect (secure, artistic or both) may also be controlled by choosing the correct type of laser such as YAG or CO<NUM>, as well as the pulse rate and speed or combination of laser types. Note that lasers may be used to impart colored personalization, static art or other desired images to the core layer and to other selected layers before or after lamination. The imparting of images may be in the form of laser engraving, oxidizing, pattern annealing, carbon migration, layer removal or any form of laser marking known in the art.

<FIG> shows a card assembly <NUM> (a "sandwich") ready to undergo embossing and lamination. <FIG> shows an embossing plate 140b having a surface 141b which has been shaped to define an image, pattern or design, which is to be imparted to the outer surface of layer 106b of the assembly <NUM>. The embossing plate 140b may be of any suitable material such as brass, stainless steels or any suitable material, and be shaped by engraving or by any known and suitable process. A top lamination plate 142a is shown located above the assembly <NUM> and a bottom lamination plate 142b is shown located below embossing plate 140b. The lamination plates cause the embossing plate 140b to be applied to the plastic layer 106b under preselected temperature and pressure. The temperature (e.g., between Tg and Tm) and pressure (e.g., between <NUM> bar and <NUM> bar (<NUM> and <NUM> PSIA)) applied during the lamination step causes the transfer of the image on the face <NUM> of the embossing plate to the laser reactive copolymer layer 106b in very fine detail. Thus, during the embossing and lamination step, the copolymer layer 106b is pushed into the grooves of the embossing plate 140b, creating a permanent, raised appearance when laminated. The depth of the embossing may range from <NUM>,<NUM> to <NUM>,<NUM> (<NUM>" to <NUM>") and may be holographic in nature. The temperature of the embossing and lamination during embossing is selected (predetermined) to a value between Tg and Tm to ensure the desired embossed image is set into layer 106b.

Another significant aspect of the invention is that the embossed pattern alters the surface and body of layer 106b without substantially affecting the adjacent layers (e.g., layer <NUM> shown below layer 106b in <FIG>). This is illustrated in <FIG> which shows the cross section of a card formed in accordance with the invention. The embossed pattern is confined to layer 106b. The type of embossing performed in accordance with this aspect of the invention may be termed "surface embossing". By this is meant that the indentations (impressions or depressions) are limited to the surface and body of the layer (e.g., 106b or 106a) being embossed and there are no corresponding indentations on the surfaces of the adjacent layers. In effect, the excess plastic material flows into the embossing plate which is manufactured (with appropriate voids) to absorb (accept) the excess material.

A significant benefit and result of the invention is that the embossed pattern formed on and within layer 106b is scratch resistant due to the hardness (firmness) of the pattern formed in the layer. In addition, any scratching of the surface is masked/minimized. The material itself conforms to a more scratch resistant geometry and material state, and additionally draws the eye away from any scratches. The reflectivity of light incident on the surface (see <FIG>) causes any scratch to be camouflaged. Also the texture or feel of the card may be readily sensed.

<FIG> shows that an assembly <NUM> can be formed in which a subassembly <NUM> can be modified with the addition of a laser reactive copolymer layer 106a overlying laser reactive film layer <NUM>. The assembly <NUM> can be laser treated before an embossing and lamination step or after an embossing and lamination step, as shown in <FIG> for assembly <NUM>. The assembly <NUM> (a "sandwich") shown in <FIG> may be ready to undergo embossing and lamination. Note that the assembly ("sandwich") subjected to embossing could alternatively be sub-assembly <NUM> or any suitable subassembly comprised of a plurality of plastic layers or a different hybrid assembly comprised of plastic layers and metal layers instead of assembly <NUM>.

<FIG> shows an embossing plate 140a having a surface 141a which has been shaped to define an image, pattern or design, which is to be imparted to the top layer (or layers) of the assembly <NUM>. As noted above for <FIG>, the embossing plate may be of any suitable material. A top lamination plate 142a is shown located above embossing plate 140a and a bottom lamination plate 142b and embossing plate 140b (as shown in <FIG>) are shown located below assembly <NUM>. The lamination plates (142a, 142b) cause the embossing plates 140a and 140b to be applied to the underlying plastic layers 106a and 106b under preselected temperature and pressure. The predetermined temperature is above the Tg of layers 106a and 106b and below their Tm. The preselected pressure is generally between <NUM>,<NUM> bar and <NUM>,<NUM> bar (<NUM> and <NUM> PSIA-). The lamination and embossing step(s) causes the transfer of the image(s) on the faces 141a and 141b of the embossing plates to the laser reactive copolymer layers in very fine detail. During the lamination and embossing step, the copolymer layers (106a, 106b) are pushed into the grooves of their respective embossing plates, creating a permanent, raised appearance when laminated. The depth of the embossing may range from <NUM>,<NUM> to <NUM>,<NUM> (<NUM>" to <NUM>") and may be holographic in nature. A resultant card would have a cross section of the type shown in <FIG> displaying various optical and textural characteristics. Thus as discussed for <FIG>, above, <FIG> illustrates that an embossing plate 140a can be applied to the top of an assembly and that an embossing plate 140b can be applied to the bottom of the assembly to form a card embodying the invention. The assembly <NUM> so configured and with embossing plates 140a, 140b would undergo lamination as discussed above. A resultant card would have a cross section of the type shown in <FIG>. As noted above, the embossed surfaces of the cards embodying the invention are scratch resistant due to the nature of the copolymer layers selected for use.

<FIG> shows that a card embodying the invention may include (going from top to bottom of the figure) a laser reactive copolymer layer <NUM> (same as layer 106a, or 106b), intermediate layer(s) <NUM>, a core layer <NUM>, intermediate layer(s) <NUM> and a laser reactive layer/mag stripe layer <NUM>/<NUM>. The layers <NUM>, <NUM> and <NUM> have been discussed above. Each one of intermediate layers <NUM> and <NUM> may include a colored PVC layer to impart a color to the card and/or an easily printable surface. Intermediate layers <NUM> and <NUM> may also include additional layers to try to provide some vertical symmetry about the core layer and between the front and back of the card.

<FIG> is a top view of a card embodying the invention. It shows the texture of the card. <FIG> shows the window that must be created in the various layers to provide a cavity for the IC chip or module <NUM> and the connection of its leads to the contacts at the top surface of the card. Note that the card could be made with the contacts on the bottom surface of the card (i.e. exiting at layer <NUM> or <NUM>). <FIG> is an exploded view of the layers of a card formed in accordance with the invention. The layers may corresponds to a card of the type shown in <FIG> or <FIG>, where the card is a smart card.

During card construction, the core layer <NUM> (metal substrate) may be treated with a laser, as shown in <FIG>, to produce a variety of optical results. As the core layer is a metal, by selecting the correct wavelength and controlling the laser power the metal substrate may be treated with the laser to turn its surface from its native color to a more dull finish, or even black, or a variety of other 'rainbow' colors. This is often termed laser color annealing. By controlling the color and contrast, a variety of desired images may be produced. In addition, the layers may be treated with the laser to provide personalization information such as account number, expiration, or account holder name.

<FIG> shows some typical thicknesses of the layers of a card embodying the invention. In an embodiment of the invention shown in <FIG> the thickness of the various layers was selected as follows:.

Note: The dimensions are illustrative only and the thickness of the various layers may be varied considerably in other cards embodying the invention.

Novel features of this invention include creating a transactional card with a physically embossed surface, the creation of such a surface using a lamination process which emulates a traditional gravure process, and the specific advantages of the embossing layer are described below.

The embossed layer provides several advantages over previous hybrid cards.

Processes for forming cards embodying the invention are shown in <FIG> and <FIG>. The process is a pseudo-gravure method, combining embossing and lamination. A general process flow follows:.

Similarly, the layers shown in <FIG> can be processed individually or in some combination and then stacked in a lamination and embossing assembly as shown in <FIG>. Generally, the layers may be treated by the application of lasers before and/or after being stacked, as discussed above. After completing the treating and assembling of all the layers, the "sandwich" is then inserted between the embossing plate(s) and subjected to the lamination and embossing process. Note that laser treatment can also be performed after embossing and lamination. The processing of the cards and their lamination and embossing can be accomplished by assembling all the components into one assembly and then laminating and embossing that assembly. Alternatively, as indicated in <FIG>, a prelamination step is possible. According to this arrangement an assembly (e.g., like <NUM>) comprising all the layers of the card except the copolymer layers (106a, 106b) would be laminated together. This prelaminate can then be inkjeted, screen printed, tampo printed, hot stamped, or printed in any suitable manner to create additional artwork or functional features. This prelaminate can then be combined with selected copolymer layer(s) to form a final assembly (e.g., like <NUM> or <NUM>) which is then subjected to embossing and lamination. Utilization of a plastic embossed layer, rather than an etched or milled, metal embossed layer has an advantage when using a laser artwork or personalization technique. When applying a laser to a patterned metal surface, non-uniform coloring often occurs in raster like pattern due to the beam "skipping" across the patterned surface. With an identical, plastic, embossed pattern, the beam can penetrate the 3D structure of the embossed material, which creates a uniform color line without optical raster.

This artwork complements and is complemented by the embossed, laser reactive copolymer on the outside of these layers. In addition to artwork, the layers may be treated with the laser to provide personalization information such as account number, expiration, or account holder name in black, white, or any suitable color.

Claim 1:
A multilayered card comprising:
an amorphous laser-reactive copolymer layer having top and bottom surfaces, said amorphous laser-reactive copolymer layer having a glass transition temperature (Tg) and a melting temperature (Tm), wherein said amorphous copolymer layer enters a crystalline state and is then settable to a set form when its temperature is above Tg and below Tm;
a selected pattern embossed on, and within, said copolymer layer at a predetermined temperature above Tg and below Tm for setting the selected pattern within said copolymer layer; and
a plurality of additional layers attached to the bottom surface of said amorphous laser reactive copolymer layer, said amorphous laser-reactive copolymer layer comprising an outer layer of the card attached to one side of a thermoplastic layer whose other side is attached to a metal core layer which in turn is attached to a laser reactive layer.