Patent ID: 7544266

Claim:
A process for laminating sheets of a core substrate layer to produce sheets of core stock used in composite laminate sheets each comprising a plurality of sections which can be cut into individual cards, comprising the steps of: continuously feeding a supply of generally flat sheets of a core substrate layer of a single material to a lamination nip; continuously feeding an intermediate film or foil layer to the lamination nip, wherein the intermediate film or foil layer includes at least one security, functional or decorative feature or layer on a surface of the intermediate film or foil layer for each of the plurality of sections; wherein the at least one security feature or layer comprises holographic imagery characterized by at least one of a holographic pattern, a custom image having demetallization of a vacuum deposited metal or other compounds or high refractive index, morphing holograms, barcodes, machine readable images, or arrays, or an ink or additive having at least one characteristic of UV fluorescent, photoluminescent, phosphorescent, IR absorbing/reflecting, color shifting (OVI or OVD), thermochromic, photochromic, taggants, markers, tracers, barcodes, readable images, arrays, or tamper-evident elements, or a vacuum deposited metal surface having at least one characteristic of being continuous, demetallized, brushed, or having decorative images, security images or effects, or UV or IR or optically variable components; wherein the at least one functional feature or layer comprises a performance coating or treatment having at least one characteristic of heat resistance, chemical resistance, UV resistance, abrasion resistance, modified coefficient of friction or antistatic property; wherein the at least one decorative feature or layer is at least one of a tint coat, texture coat, graphics, indicia, woodgrain, argent, stone or marble pattern; laminating the intermediate film or foil layer to the sheets of core substrate layer to produce sheets of core stock; and producing; the composite laminate sheets, by additionally applying; at least one print layer or at least one overlay layer, to an outer surface of intermediate film or foil layer wherein the at least one security, functional and/or decorative feature or layer for each of the plurality of sections are buried between the intermediate film or foil layer and the core substrate layer.