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EP-4742089-A2 - TRANSACTION AND ID CARDS HAVING SELECTED TEXTURE AND COLORING

EP4742089A2EP 4742089 A2EP4742089 A2EP 4742089A2EP-4742089-A2

Abstract

Cards made in accordance with the invention include a specially treated thin decorative layer attached to a thick core layer of metal or ceramic material, where the thin decorative layer is designed to provide selected color(s) and/or selected texture(s) to a surface of the metal cards. A method for making cards with a given appearance comprising the steps of: selecting a decorative layer, said decorative layer comprising an aggregate binder material veneer layer comprising a layer of cement or epoxy mixed with laser reactive carbon particles; selecting a core layer for forming the body of said card, said core layer having first and second surfaces generally parallel to each other; said core layer being: (a) metal; or (b) a ceramic coated metal; or (c) a ceramic coated polymer, or (d) a solid ceramic material, and attaching said decorative layer to the first surface of the core layer; and applying a laser source to said layer of cement or epoxy mixed with laser reactive carbon particles to vaporize the laser reactive carbon particles and produce a pattern with high contrast.

Inventors

  • HERSLOW, JOHN
  • LOWE, ADAM
  • DASILVA, LUIS

Assignees

  • Composecure LLC

Dates

Publication Date
20260513
Application Date
20150521

Claims (14)

  1. A method for making cards with a given appearance comprising the steps of: selecting a decorative layer, said decorative layer comprising an aggregate binder material veneer layer comprising a layer of cement or epoxy mixed with laser reactive carbon particles; selecting a core layer for forming the body of said card, said core layer having first and second surfaces generally parallel to each other; said core layer being: (a) metal; or (b) a ceramic coated metal; or (c) a ceramic coated polymer, or (d) a solid ceramic material, and attaching said decorative layer to the first surface of the core layer; and applying a laser source to said layer of cement or epoxy mixed with laser reactive carbon particles to vaporize the laser reactive carbon particles and produce a pattern with high contrast.
  2. The method of Claim 1 wherein said step of attaching said decorative layer to a core layer includes the step of forming a pocket within a surface of said core layer and firmly attaching one of said decorative layers within said pocket.
  3. The method of Claim 2, wherein the depth of the pocket is made substantially equal to a thickness of the decorative layer.
  4. The method of any one of Claims 1 to 3, wherein said decorative layer is a first decorative layer, further including the step of attaching a second decorative layer to the second surface of the core layer.
  5. The method of Claim 4, wherein said second decorative layer attached to the second surface of the metal layer includes one of (a) an anodized metal layer, (b) a plant derived material veneer layer; (c) an animal derived material veneer layer; (d) an aggregate binder material veneer layer; (e) a ceramic layer; and (f) a layer of crystal fabric material.
  6. The method of any one of Claims 1 to 5, wherein the laser source is applied only to said layer of cement with laser reactive carbon particles to vaporize the laser reactive carbon particles and produce a pattern with high contrast.
  7. The method of any one of Claims 1 to 6, wherein the first surface of said core layer has a pocket and wherein the decorative layer is attached to the core layer within the pocket.
  8. A card having a front side and a back side, said card comprising: a core layer; said core layer forming the bulk of the card and having a predetermined color and said core layer having first and second surfaces extending generally parallel to each other; and a decorative layer attached to said first surface of said core layer for providing at least one of color and texture to the card, said decorative layer comprising an aggregate binder material veneer layer comprising a layer of cement or epoxy mixed with laser reactive carbon particles having a pattern formed in said veneer layer due to vaporization of the carbon particles.
  9. The card of Claim 8 wherein said decorative layer attached to the first surface of said core layer is a first decorative layer; said card having a second decorative layer attached to the second surface of said core layer.
  10. The card of Claim 9, wherein said second decorative layer comprises one of: (a) an anodized metal layer, (b) a plant derived material veneer layer; (c) an animal derived material veneer layer; and (d) an aggregate binder material veneer layer; (e) a ceramic layer; and (f) a layer of crystal fabric material.
  11. The card of Claim 9 or Claim 10, wherein the first decorative layer attached to the first surface of said core layer is different from the second decorative layer attached to the second surface of said core layer.
  12. The card of any one of claims 9 to 11, wherein the second decorative layer comprises an anodized metal foil, the card further comprising a signature panel and a magnetic stripe attached to the second decorative layer.
  13. The card of any one of Claims 9 to 11, wherein the second decorative layer comprises an anodized metal foil, the card further comprising a polymer layer attached to the second decorative layer and a signature panel and a magnetic stripe attached to the polymer layer.
  14. The card of any one of Claims 8 to 12, wherein the first surface of said core layer has a pocket and wherein the decorative layer is attached to the core layer within the pocket.

Description

BACKGROUND OF THE INVENTION This application claims priority based on a provisional application titled TRANSACTION AND ID CARDS WITH CONTROLLED COLORING bearing serial number 62/001706 filed May 22, 2014, whose teachings are incorporated herein by reference. This application also claims priority based on a provisional application titled CERAMIC TRANSACTIONAL AND IDENTIFICATION CARDS WITH CONTROLLED COLORING bearing serial number 62/074305 filed November 3, 2014, whose teachings are incorporated herein by reference. This invention relates to the manufacture of metal cards having varied coloring and texture. In particular, the present invention relates to apparatus and methods for producing transactional and ID cards, or any like document, having a metal layer where the card can be made to have a variety of colors and textures. This invention also relates to cards having a core layer of ceramic material and to metal cards with decorative ceramic layers. It has become desirable to provide metal or ceramic cards for the high end market to impart a sense of wealth and distinction to the card holder. It is also desirable to provide metal cards with different colors and textures to further enhance eye and touch appeal and/or provide a degree of personalization. It is known to use physical vapor deposition (PVD) to color metal transaction cards, but PVD is limited in its color range and is also relatively expensive. PVD is also highly dependent upon the substrate upon which it is being deposited. PVD is a vacuum process with high heat and batch operation that is expensive requiring individual racking and turning of parts for even distribution of color. It also subjects the metal to high temperature which can shrink and warp the metal. In some metal cards, printed PVC layers or other polymers are used to decorate the outside of cards. The use of these polymeric layers has undesirable traits such as minimum print thickness, loss of weight in the metal card due to polymeric thickness, and challenges of lamination of dissimilar materials. Use of different thicknesses and compounds can also cause the parts to warp or bow due to uneven shrinkage during platen lamination. It is an object of this invention to overcome these and other problems and to enable the manufacture of metal cards and/or ceramic cards having a wide range of colors and textures. SUMMARY OF THE INVENTION Cards made in accordance with the invention include a specially treated thin decorative layer attached to either side, or both sides, of a thick core layer of metal, ceramic coated metal or polymer, or solid ceramic material, where the thin decorative layer is designed to provide selected color(s) and/or selected texture(s) to a surface of the cards. Decorative layers for use in practicing the invention include: (a) an anodized metal layer; or (b) a layer of material derived from plant or animal matter (e.g., wood, leather); or (c) an assortment of aggregate binder material (e.g., cement, mortar, epoxies) mixed with laser reactive materials (e.g., finely divided carbon); or (d) a ceramic layer; and (e) a layer of crystal fabric material. The cards may be dual interface smart cards which can be read in a contactless manner and/or via contacts. The manufacture of metal cards in accordance with the invention includes the preparation and treatment of a generally thin decorative layer and attaching the decorative layer to a thick metal substrate; where the thin decorative layer is designed to provide selected color(s) and/or selected texture(s) primarily to the front surface of the metal cards but also to the back of the cards. Where the thin decorative layer is an anodized metal layer, the metal layer is prepared and treated to have a selected color for imparting the coloring to the card. Adding color (colorizing) to metal layers by anodizing is preferable to the PVD process for several reasons. Anodizing is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. Thus, coloring a metal by anodizing is highly desirable. Aluminum is ideally suited to anodizing. However, other nonferrous metals, such as magnesium, titanium, zinc, niobium, tantalum, or any other metal which can be anodized, can be used to practice the invention. As for aluminum films, for example, the anodic oxide structure originates from the aluminum substrate and is composed entirely of aluminum oxide. This aluminum oxide is not applied to the surface like paint or plating, but is fully integrated with the underlying aluminum substrate, so it cannot chip or peel. It has a highly ordered, porous structure that allows for secondary processes such as coloring and sealing. Anodizing may be accomplished by immersing the aluminum into an acid electrolyte bath (tank) and passing an electric current through the medium. A cathode is mounted to the inside of the anodizing tank; the aluminum acts as an anode, so that oxygen ions