Card with embedded image

Abstract

A card includes a layer of deformable material embossed with a three dimensional (3-D) pattern. A first layer is in direct contact with and overlies the embossed deformable layer. A second layer is in direct contact with and underlies the embossed deformable layer. The first layer is of conformable material and extends within the embossed pattern for filling, setting and maintaining the embossed pattern in a fixed condition. The second layer is of conformable material and conforms to the embossed pattern set in the deformable layer.

Claims

1. A card comprising: a layer of deformable material embossed with a three-dimensional (3-D) pattern, the layer of deformable material consisting of a single layer of the deformable material comprising a deformable metallic foil; a first layer in direct contact with and overlying the layer of deformable material; a second layer in direct contact with and underlying the layer of deformable material; said first layer being of conformable material that extends into and fills the three-dimensional pattern for filling, setting and maintaining the three-dimensional pattern formed on the single layer of the deformable material in a fixed condition; said second layer being of conformable material that conforms to and fills the embossed pattern formed on the single layer of the deformable material such that the embossed pattern set in the layer of deformable material protrudes into portions of the second layer; a first set of additional layers overlying the first layer and a second set of additional layers underlying the second layer, wherein the first set of additional layers has a first layer of semi-conforming material directly overlying the first layer and the second set of additional layers includes a second layer of semi-conforming material directly underlying the second layer; and wherein said second layer of semi-conforming material includes a printed pattern or image configured to block all or portions of the embossed pattern.

2. The card as claimed in claim 1 wherein the three- dimensional pattern is comprised of elements whose shape is rectilinear, the elements comprising generally straight lines that are orthogonal to each other.

3. The card as claimed in claim 1, wherein said first and second sets of additional layers secure the embossed pattern and level the outer surfaces of the card and cause the outer surfaces to be uniformly flat.

4. The card as claimed in claim 3, wherein the optical characteristics of the layer of deformable material, the first layer, the second layer, the first set of additional layers, and the second set of additional layers enable the embossed pattern to be viewed from the underlying front side.

5. The card as claimed in claim 3, wherein the first set of additional layers overlying the first layer further includes a first leveling layer; and wherein the second set of additional layers in front of and underlying the second layer further includes a second leveling layer; and wherein the first and second leveling layers are composed of a material for leveling the outer surfaces of the card and causing them to be uniformly flat.

6. The card as claimed in claim 5, wherein said first and second sets of additional layers and said first and second layers of semi-conforming material are formed from a material selected from PVC, amorphous PET including PETG, Polyethylene or any thermo plastic material.

7. The card as claimed in claim 1, wherein: (a) a thickness of the layer of deformable material ranges from 0.0005 inches to 0.003 inches; (b) a thickness of the first and second layers ranges from 0.002 to 0.008 inches; wherein the card further comprises a first additional conforming and leveling layer overlying the first layer and a second additional conforming and leveling layer underlying the second layer, and wherein the thickness of the first and second additional layers ranges from 0.002 to 0.008 inches; wherein the card further comprises a first additional leveling layer overlying the first additional layer and a second additional leveling layer underlying the second additional layer, and wherein the thickness of the first and second additional leveling layers ranges from 0.001 to 0.012 inches, said second layer being of conformable material and conforming to the embossed pattern set in the layer of deformable material.

8. The card as claimed in claim 1, wherein said first layer of semi-conforming material is opaque.

9. The card as claimed in claim 1, wherein optical characteristics of the deformable metallic foil and at least one of the first layer and second layer are selected to enable all or portions of the embossed pattern to be visible from at least one of a top outer surface or a bottom outer surface of the card.

10. The card as claimed in claim 9, wherein all or portions of the embossed pattern are visible only from one of the top outer surface or the bottom outer surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the accompanying drawings, which are not drawn to scale, like reference characters denote like components, and:

(2) FIG. 1 is an idealized symbolic cross-sectional view of the layers of a card embodying the invention;

(3) FIG. 2 is an idealized symbolic cross-sectional diagram of layers and associated components used to form one portion (e.g., the upper portion) of a card embodying the invention;

(4) FIG. 2A is an idealized cross-sectional diagram of a lamination process in accordance with the invention;

(5) FIG. 2B is a simplified cross sectional diagram illustrating the raised (embossed) pattern formed on and within (or extending from) the outer surface of the foil layer 100 and the overlying (back) layers;

(6) FIG. 2C is a top view of a card showing a pattern formed following the application of an engraving plate during a lamination process as set forth in FIGS. 2, 2A and 2B;

(7) FIG. 3 is a simplified cross-sectional view of layers used to form another portion (e.g., the lower portion) of a card embodying the invention;

(8) FIG. 3A is an idealized cross-sectional diagram of the stacking and lamination of upper and lower assemblies in accordance with the invention;

(9) FIG. 3B is an idealized cross-sectional diagram of an embossed layer embedded between conforming layers in accordance with the invention;

(10) FIG. 4 is an idealized cross-sectional view of additional layers which may be added to the layers shown in FIG. 3;

(11) FIGS. 5, 5A, 5B and 5C are conceptual cross sectional view illustrating a prior art method of forming a pattern on a card; and

(12) FIG. 6 is a highly simplified diagram of a continuous system using rollers to make cards in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

(13) FIG. 1 shows the structure of a card embodying the invention which projects a three dimensional (3-D) image or pattern while actually having uniformly flat top and bottom external surfaces. A layer 100, embedded between two layers 102a and 102b of conformable material, is embossed with a desired pattern. A layer 102a of conforming material is formed above layer 100 and a layer 102b also of conforming material is formed below layer 100. The layer 100 is formed of a material which is deformable and malleable. The material of layer 100 may be metallic (e.g., a foil) or any other suitable non-metallic material having a sufficiently high reflective or refractive index to enable the formation and display of a well defined optical contrasting image. The deformable embedded layer 100 can be plain metal, holographic (including HRI), registered holographic, dyed in color, printed, or any combination of the above. To produce a visible image, the deformable layer and the overlying and underlying layers laminated with it are selected to have contrasting colors and/or different refractive indices, including optically reflective material. The layer 100 is generally very thin (e.g., microscopic). For example, it may range in thickness from 0.0005 inches to 0.003 inches. The layer 100, when engraved, may have a pronounced and patterned three dimensional (3-D) image produced in accordance with this invention. The 3-D image which may be purely decorative can be either clear or opaque. The laminated card will have uniform and flat top and bottom surfaces.

(14) The layers 102a and 102b are formed of pattern conforming material which, in this context, means that the material of these layers when placed under appropriate selected temperature and pressure will flow (or deform) readily to conform and adhere to the pattern embossed in the embedded layer 100 while providing a leveling effect on the side of layers 102a, 102b facing away from the embossed layer 100. After the layers 102a and 102b are made to conform to the embossed layer they will remain set to the shape unless the selected temperature is exceeded. Thus, any material having these properties may be used as layers 102a, 102b to practice the invention. Some typical materials used to practice the invention include, but are not limited to, polyvinyl chloride (PVC), amorphous polyester terepthalate (PET) including PETG, polyethylene or any thermo plastic material. The thickness of layers 102a, 102b, may range from less than 0.002 inches to more than 0.008 inches. Layers 102a, 102b may also be referred to as adhesive layers since they are designed to adhere to the deformable patterned layer 100.

(15) Then, there is a layer 104a of semi-conforming material formed above (in back of) layer 102a and a layer 104b also formed of semi-conforming material below (in front of) layer 102b. Layers 104a and 104b provide similar filling (conforming) and leveling and adhering functions to those provided by layers 102a and 102b. However, layers 104a, 104b need not be as conformable as layers 102a, 102b. Some typical materials used to practice the invention include PVC, PET, PE [provide full names]. The thickness of layers 104a, 104b, may range from less than 0.001 inches to more than 0.012 inches.

(16) As shown in FIG. 1, the semi-conforming 104b layer may include preprinted data or a printed layer. The printed layer may be used to mask or block portions of the 3-D pattern formed on layer 100.

(17) Then there is a standard PVC layer 106a formed above (in back of) the semi-conforming layer 104a and a similar standard PVC layer 106b formed below (in front of) the semi-conforming layer 104b.

(18) Note that there is a high degree of symmetry in the formation of layers 102a, 102b, 104a, 104b, 106a and 106b above and below layer 100 so that warping and distortion of the card due to environmental responses of the various layers is limited. Also, as the card is formed (see below) the top surface of layer 106a and the bottom surface of layer 106b tend to be uniformly flat.

(19) FIG. 1 also shows a PVC layer 108b formed below (in front of) layer 106b. Layer 108b may include printed data and may be opaque or transparent. The pattern embossed on, or within, layer 100 can be read/seen from the bottom (front) side as shown in FIG. 1. It should be understood that the terms above (a) and below (b) as used herein are purely arbitrary and applied for ease of illustration and explanation. The explanation applies equally if the drawings and the card are inverted 180 degrees.

(20) The card shown in FIG. 1 may be formed in two (or more) laminating steps as detailed in FIGS. 2, 3 and 4. FIG. 2 illustrates that a first assembly 120 is formed comprising a layer 100 of deformable material overlying which is a layer 102a of conformable material overlying which is layer 104a of semi-conformable material 106a. The assembly or sandwich 120 is also arbitrarily referred to as the top (back) portion 120 of the card, the first assembly and/or the build up 120a. The assembly 120a is embossed and laminated as discussed below.

(21) An engraved laminating plate 90 is chemically etched with a pattern. The plate 90 may also be laser etched or engraved by any number of known mechanical or electrical means. Thus a step in the process includes preparing an engraved laminating plate, 90, engraved with the desired pattern to be transferred to the card.

(22) Assume that the deformable layer 100 is a foil layer and that the engraved laminating plate is applied to the bottom (front) side of foil layer 100 (as shown in FIGS. 1 and 2) to generate an embossed pattern on, and within, the foil layer 100 facing towards the front of the card (i.e., the embossed pattern will be facing towards the Read Me side shown in FIG. 2

(23) FIGS. 2, 2A, and 2B, illustrate the formation of a first assembly or sandwich 120a comprised of the following four layers: ia (holographic) foil layer (e.g., 100) of a (highly) deformable material to be placed against the engraved laminating plate 90 to form an embossed pattern on the foil layer, 100; iia first layer 102a of a pattern conforming plastic material placed above (in back of) the foil layer (e.g, 100); iiia first additional layer 104a of a semi-conforming material placed above the layer 102a; where layer 104a may be clear or opaque; and ivA standard PVC layer 106a placed above layer 104a.

(24) The layers 100, 102a, 104a, and 106a, forming assembly 120a, are placed between the engraving laminating plate 90 and a matte laminating plate 80 with the front surface of foil layer 100 facing the engraving plate 90. Plates 80 and 90 function as opposing lamination plates across sandwiched layers 120a. The foil layer 100 is embossed with the engraved pattern and the layers 100, 102a, 104a and 106a are laminated at the same time by the application of heat and pressure to the subassembly 120a. During the lamination and engraving processing step of the first assembly 120a, laminating plate 80 and engraving laminating plate 90 are used to engrave layer 100 and to apply heat and pressure to the intermediate layers 102a, 104a and 106a to soften the materials constituting the layers and to reduce their respective viscosities.

(25) Applying pressure and heat to assembly 120a causes the metallic foil layer 100 to be forced (pressed) into the engraved cavities in the laminating plate 90 to conform to the desired engraved pattern. Concurrently, material from conformable layer 102a and semi-conformable layer 104a flow into, and fill, the cavities (embossments) imparted to the foil layer 100 by, and with, the engraving plate 90. Concurrently, the layers 102a, 104a and 106a combine to provide leveling for the top surface of layer 106a of assembly 120a. The top surface of layer 106a may thus be uniformly level. Thus, when the engraved laminating plate 90 (and the laminating plate 80) is removed, an embossed pattern may be fixed into the layer 100 and set into the front of the assembly, as shown in FIG. 2B

(26) A matte finished laminating plate 80 is used to prevent air bubble entrapment which may result from the use of polished plates. When a matte finish is used, any air entrapped by (and or between) the surfaces of the polished plate and the surface of the plastic being laminated leaves via valleys produced in a matted surface. Alternatively, A vacuum laminator may be used to suck out the air that causes bubbles eliminating the need to use matte plates or allowing the use of polished plates.

(27) In FIGS. 2, 2A and 2B, the engraved laminating plate 90 is shown positioned below the layer 100 and is applied during the engraving and lamination of the first assembly 120a to the bottom (front) side of layer 100. After lamination, the resultant sheet containing assembly 120a will have an embossed pattern protruding towards the bottom in the figures which corresponds to the front of the card (the Read Me side). As discussed, layers 102a and 104a are selected to have properties which will cause them to provide filling material in the raised embossment (protrusions) formed in layer 100 during engraving and lamination. Concurrently layer 106a in combination with layers 102a and 104a function to complete the filling process and provide a uniformly flat surface above 106a. The total thickness of the build up (or top assembly) 120a may be in the range of 0.004 to 0.015 for an ISO card. However, it should be evident that the thickness of the top assembly 120a may be less or significantly greater.

(28) The build up (or top assembly) 120a is formed at a relatively high temperature and pressure to cause the material of the deformable layer 100 to be malleable and engravable by engraving plate 90 and the material of layer 102a (and of layer 104a) to flow into the embossed regions engraved into layer 100. By way of example, in one embodiment the lamination of layers 100, 102a, 104a and 106a to form a first assembly 120a was done at a platen temperature of 300 degrees Fahrenheit and a pressure of 350 PSIA. [Note these are given for purpose of illustration and a wide range of temperature and pressure may be used where appropriate for the materials used.] In one embodiment of the invention, the thickness of the various layers was approximately as follows: the foil layer 100 was 0.002 inches, the conforming layer 102a was 0.003 inches, the semi-conforming (white) leveling layer 104a was 0.0065 inches, and the over lying PVC clear laminate layer 106a was 0.002 inches, whereby the build up 120a was approximately 0.0135 inches.

(29) FIGS. 2A and 2B are intended to illustrate that during the lamination process layer 100 will deform to conform to the shape/pattern of the engraved plate 90 and layer 102a will melt and press down on, and within, layer 100 to ensure that that the engraved pattern is transferred to and set in layer 100 and in layer 102a in back of layer 100. This step is critical in the creation of a sharp detailed pattern in the foil layer 100 and is in sharp contrast to known schemes.

(30) FIG. 2B illustrates that at the end of the first stage of lamination, (also referred to as step 1) an assembly 120 is formed containing an embossed pattern formed within the foil layer 100 which is, essentially, a raised 3-D image. This image has very sharp and well detailed lines and is shown to protrude toward the bottom of the page in FIG. 2B (the front of the card). By proper selection of the materials constituting layers 102a, 104a and 106a the outer (upper) surface of layer 106a, after lamination, is smooth and uniformly flat. It is significant to note that, in accordance with invention, the embossed pattern may be termed to be rectilinear in that the pattern is formed with straight lines which are generally perpendicular to each other. Note that the rectilinear condition extends to the portion of layer 102a most directly in contact with patterned layer 100.

(31) FIG. 2C illustrates a possible pattern (e.g., CompoSecure) created by the application of the engraved plate 90 to the assembly 120a and subjecting the assembly 120a to the relatively high temperature and pressure described above. This illustrates that the resulting card will have a sharp, well defined, image formed on the outer surface of embossed layer 100.

(32) In accordance with the invention, the appearance of the image and its 3D quality formed on, and in, layer 100 of sub-assembly 120a is secured and preserved by the addition of an additional assembly 120b as shown in FIG. 3. However, the lamination of sub-assemblies 120a and 120b is conducted at a lower temperature than the temperature used to laminate 120a to prevent the softening of layer 102a and the disturbance of the embossed pattern.

(33) FIGS. 3 and 3A shows the formation of a bottom or front portion also referred to as the second assembly 120b, of a card. In FIGS. 3 and 3A, layers 102b, 104b and 106b are positioned in layers below (in front of) the embossed layer 100 and then laminated onto the bottom (front) surface of section 120a. Layer 102b may be similar to layer 102a; layer 104b may be similar to layer 104a; and Layer 106b may be similar to layer 106a. Layer 102b is of a pattern conforming material so as to conform to the pattern embossed on layer 100. Laminating plates 800 and 802 are used to apply heat and pressure to the combined assemblies 102a, 102b, as shown in FIG. 3A, to laminate the two assemblies to form a card product 122 with an embedded pattern between conforming layers 102a and 102b. Following lamination of the two assemblies, a resultant product is shown in FIG. 3B.

(34) Note that the pattern embossed on the first assembly functions to define the pattern to which the second assembly conforms. Note also that, generally, less pressure and a lower temperature is used during the lamination step for combining assemblies 120b and 120a than during the lamination step forming the top assembly 120a. This is done in order to avoid deforming the 120a assembly and adversely affecting the integrity of the embossment.

(35) Layer 104b is of a semi-conforming material similar to layer 104a. Layer 104b (or layer 106b) can be patterned or printed to create a mask or window to allow the display of part or all of the overlying (or underlying) embossment (image or pattern). Alternatively, layer 104b (or 106b) can be entirely clear to allow the projection and display of the entire area of the embedded and embossed layer 100. For the embodiment shown in FIG. 3, the embossed pattern will face the card side labeled Read Me. As noted above, after the lamination steps the outer surfaces of layers 106a and 106b will be smooth and uniformly flat. Laminating plates 800a and 800b may both be polished finished laminating plates to provide a final finished polish. The fully assembled product 122, (which may be used as a card, or part of a card, embodying the invention) has the desirable features that its embossed pattern is embedded between two conforming layers which ensure the setting, protection and maintenance of the embossed pattern. The embossed pattern provides a well defined and very precise three dimensional (3-D) image because of the use of engraved plates to form the pattern. It should be appreciated as already noted above, that the embossed pattern may be termed to be rectilinear in that the pattern is formed with straight lines which are generally perpendicular to each other. Note that the rectilinear condition extends to the portions of layer 102a and 102b most directly in contact with patterned layer 100. The presence of these straight lines helps produce well defined images. The resulting images may be, for example, lines, type, logos, and reliefs and have any possible shape.

(36) FIG. 4 shows the addition of a layer 108b to the front of (and underlying) layer 106b. Layer 108b may be a PVC layer with printed data and or it may be opaque. The embossed image can be seen from the front side (e.g., Read Me) and the debossed image can be seen from the back side if the materials in back of layer 100 are clear. The lamination of layer 108b to the assembly 122 can take place at temperatures comparable to those used to laminate assembly 120a to assembly 120b. However, the pressure exerted will be slightly higher than that exerted in the lamination of 120a to 120b. As in that process, a polished finished laminating plate may be used to obtain a flat polished surface. Note that in accordance with the invention, any of the layers may be printed or preprinted to cover any desired portion of the surface area of a layer. This enables selected portions of the image to be displayed.

(37) Alternatively, layer 108b can be attached to layer 106b during the formation of assembly 102b and its attachment to assembly 102a. However, doing that results in a slight loss of clarity because lamination of both sides at once can cause material flow in both perpendicular directions causing the image to flow back (tend to revert to its original flatness).

(38) It should be noted that a colorant may be added to the recesses of the engraving plate such that there is an optical contrast on the raised portion of the deformed image. The colorant may be introduced by any known means. For example, this can be done by wiping the surface of the engraving plate with a colorant like powdered PVC or ink and cleaning off the excess with an absorbent medium like a rag.

(39) A card embodying the invention may thus be formed which meets the ISO standards and/or any desired shape or thickness.

(40) Features of the invention include finding and defining those materials having the desired flow characteristics as a function of temperature: 1In accordance with the invention, maintaining a sharp edge at the depression of the laminating plate in addition to controlling the product dimensional location on the sheet (to match printed images) are both crucial to having acceptable finished product quality. 2Maintaining a sharp edge at the depression of the laminating plate in addition to controlling the product dimensional location on the sheet (to match printed images) are both crucial to having acceptable finished product quality. 3Maintaining card flatnessWhenever a plastic material is platen laminated it shrinks. Doing several lamination steps of one side and then the other side can result in the first side shrinking more than the second side and loss of flatness of the card (e.g., bowing). By symmetrical construction of layers above and below the deformable layer and by appropriate selection of materials this problem is minimized. 4Minimizing internal surface imperfections. Because air can be trapped by crevices, which will be filled by flowing plastic, air bubbles inside the lamination surfaces can be generated. Adjusting the lamination cycles to overcome this problem can be challenging.

(41) FIG. 6 shows the use of rollers (rotating drums) to form card products embodying the invention. A sheet of deformable material corresponding to layer 100 is wrapped around a roller 602 and sheets of material corresponding to layers 102a, 104a and 106a are stacked one on top of the other and wrapped around a roller 604. The sheet of deformable material and the stacked sheets of conforming and leveling materials are pressed against each other as they are urged through and pass between engraving roller 90a and laminating roller 80a. Engraving roller 90a functions like engraving plate 90 and laminating roller 80a functions like laminating plate 80. Rollers 90a and 80a may be heated to the desired temperature and the pressure they apply to the sandwich of materials passing between them may be controlled to engrave and laminate continuously. This manufacturing step produces sheets of engraved and laminated first assemblies corresponding to first assembly 120a. Concurrently, sheets of materials corresponding to layers 102b, 104b and 106b are stacked one on top of the other and wrapped around a roller 800a. The engraved and laminated sheets outputted from rollers 80a/90a are then pressed against sheets wrapped around roller 800a and with rollers 800a and 800b applying requisite temperature and pressure to laminate the sheets and producing laminated assemblies of products corresponding to product 122. The resultant roll of material containing products 122 may be laminated with another sheet of material corresponding to layer 108b via laminating rollers 802a, 802b to produce a roll of final products corresponding to the card part shown in FIG. 4. In FIG. 6 there are 3 stages of manufacture at which different lamination steps of the manufacturing process are performed. There need be at least two stages, but here could be more than three depending on the number and, types of additional layers desired to be attached to the basic first and second assemblies.

(42) Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.