Sheet assembly for forming one or more cards

Abstract

The sheet assembly (100) can be cut into cards (102) comprising: an upper layer (124) configured to accept a first print (122); a core layer (126) coupled with the upper layer and a lower layer (128) configured to accept a second print (130) and coupled with the core layer, wherein the core layer is disposed between the upper sheet and the lower sheet. One or more of the upper layer, the core layer, or the lower layer is formed from a paper impregnated with a resin, the resin comprising a bio-based resin. The bio-based resin can comprise one or more of: plant, petroleum-based or not, cellulose, lignocellulose, natural fibers, starch, polysaccharides, fats and oils, proteins and / or alginates, kenaf, sisal, jute, hemp and flax, corn starch, potato starch, tapioca starch, pectin, chitin, levan, amylopectin, soy, rescalozier, rapeseed, casein, corn protein, soy protein, PLA, PHA, PBAT, PBS, PE, PP, PET, PUR, EPDM, PVC, PMMA, PEF, PTF, PTT, SBR, PBT, ABS, PA, APC, CA.

Description

[0001] Cross-references of related applications

[0002] This application claims priority to U.S. Application 63 / 147,898, filed February 10, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The subject matter described herein relates to multi-layer sheet assemblies that can be cut into smaller cards, such as identity cards, financial transaction cards (credit cards, debit cards, gift cards, etc.) or other types of cards. Background Technology

[0004] Cards can be used for a variety of purposes, such as identification or security, financial transactions, etc. With increasing environmental considerations and the trend towards "green" products, some manufacturers have turned to producing biodegradable cards. These cards are formed from multiple layers of paper held together by biodegradable polymers. However, these known biodegradable cards are not durable and may not withstand repeated use, humid environments, etc. For example, some such cards peel off, rendering them unusable. Some higher-end financial transaction cards are made of metal or include metal to provide a heavier card, which may be ideal for consumers. However, introducing these types of materials may make card recycling more difficult or more costly. Summary of the Invention

[0005] In one embodiment, a sheet assembly capable of being cut into one or more cards is provided. The sheet assembly includes an upper layer configured to receive a first print of a first imprint of one or more cards. The sheet assembly may also include a core layer coupled to the upper and lower layers, the lower layer being configured to receive a second print of a second imprint of one or more cards. The lower layer may be coupled to the core layer, the core layer being disposed between the upper and lower sheets. One or more of the upper layer, core layer, or lower layer may be formed of paper impregnated with a resin, including bio-based resins.

[0006] In one embodiment, a method for producing a sheet assembly may include: forming a core layer and attaching an upper layer to the core layer, the upper layer being configured to receive a first print of a first mark of one or more cards. The method may include attaching a lower layer to the core layer to form a sheet assembly including an upper layer, a core layer, and a lower layer. The lower layer may be attached to the core layer, the core layer being disposed between the upper and lower layers. The lower layer may be configured to receive a second print of a second mark of one or more cards. The sheet assembly may be configured to be cut into one or more cards. One or more of the upper layer, core layer, or lower layer may be formed from paper impregnated with a resin, including bio-based resins. Brief description of the attached diagram

[0008] The subject matter of this invention can be understood by referring to the following description of non-limiting embodiments, which are shown in the accompanying drawings:

[0009] Figure 1 A perspective view showing one embodiment of a multilayer sheet assembly;

[0010] Figure 2 An example is shown. Figure 1 The card shown is along Figure 1 The cross-sectional view obtained by cutting line 2-2 in the diagram;

[0011] Figure 3 An example is shown. Figure 1 The card shown is along Figure 1 The cross-sectional view obtained by cutting line 2-2 in the diagram;

[0012] Figure 4 An example is shown. Figure 1 The card shown is along Figure 1 The cross-sectional view obtained by cutting line 2-2 in the diagram;

[0013] Figure 5 An example is shown. Figure 1 The card shown is along Figure 1 The cross-sectional view obtained by cutting line 2-2 in the diagram;

[0014] Figure 6 An exploded view of a card according to one embodiment is shown; and

[0015] Figure 7 A flowchart illustrating a method for forming a sheet assembly according to one embodiment is shown, the sheet assembly being cut into smaller cards. Detailed Implementation

[0016] The subject matter of this invention provides a multilayer sheet assembly from which multiple cards can be cut. The cards can be formed for use as identity cards, security cards, financial transaction cards, etc. The sheet assembly can be formed from a material comprising paper impregnated with a resin. The resin can be a petroleum-based resin or a bio-based resin. Bio-based resins can include resins composed of renewable or biological resources (e.g., plants). Bio-based resins can include non-petroleum-based resins. The resin can be thermoplastic or thermosetting.

[0017] The card may include high-density particles to enhance its properties and provide a metallic weight, texture, or impact resistance. High-density particles can be provided to make the card non-conductive, thus preventing it from experiencing electrostatic discharge. The card can be manufactured using current equipment used to produce plastic cards. The card can be more durable than current plastic cards and can last up to five years or more. The card can be, for example, a financial transaction card, identity card, key card, access card, or security card.

[0018] Sheet assemblies can also be used to form other products. For example, sheet assemblies can be used to form decorative panels for cabinets, countertops, furniture surfaces, and floors.

[0019] Figure 1 A perspective view of one embodiment of a multilayer sheet assembly 100 is shown. The sheet assembly 100 may be large enough to cut out a plurality of cards 102. These cards 102 may be identity cards (e.g., driver's licenses, work ID cards, etc.), financial transaction cards (e.g., credit cards, debit cards, gift cards, etc.), and so on. In one embodiment, each card 102 has a shape and size defined by the ISO / IEC 7810ID-1 standard. Alternatively, the cards 102 may have different shapes and / or sizes. The sheet assembly 100 may be large enough to cut out a plurality of (e.g., 63 or other numbers) cards 102. For example, the sheet assembly 100 may have a surface area on each side of the sheet assembly 100, which is at least 2911 square centimeters.

[0020] Figure 2 An example is shown. Figure 1 The card shown is along Figure 1 The cross-sectional view obtained by cutting line 2-2 in the diagram. The card includes an upper transparent overlay 120 and a lower transparent overlay 132. The upper and lower transparent overlays may be formed of a polymer. In another embodiment, the upper and lower transparent overlays may be formed of resin-impregnated paper. The resin-impregnated paper may be impregnated with resin. The resin-impregnated paper may have an intermediate permeation network of paper fibers and resin polymer. The resin impregnating the paper may have resin dispersed throughout the paper or embedded in the paper. The resin-impregnated paper may have resin mixed with the paper. The resin may be provided uniformly or homogeneously in the resin-impregnated paper.

[0021] The resin may include a bio-based resin. A bio-based resin can be a resin derived from biological resources (e.g., plants). A bio-based resin can be a non-petroleum-based resin. The resin may also include petroleum-based resins. For example, resin-impregnated paper may be impregnated with a resin that is 40% bio-based and the remainder petroleum-based. According to other examples, the resin may include up to 50%, up to 60%, up to 70%, up to 80%, up to 90%, or up to 100% bio-based material, with the remainder being petroleum-based resin. According to another example, resin-impregnated paper may include a resin that is 40%–70% bio-based.

[0022] Bio-based resins that can be used in resin-impregnated paper may include bio-based polymers formed from cellulose, lignocellulose, natural fibers, starch, polysaccharides, fats and oils, proteins, and / or alginates. Examples of natural fibers may include kenaf, sisal, jute, hemp, and flax. Examples of lignocellulose may include corn starch, potato starch, or tapioca starch. Examples of polysaccharides may include pectin, chitin, fructan, or amylopectin. Examples of fats and oils may include soybean, lesquerella, and rapeseed. Examples of proteins may include casein, corn protein, or soy protein.

[0023] Bio-based polymers that can be used in resin-impregnated paper may include polylactic acid (PLA), polyhydroxyalkanoate (PHA), polybutylene adipate (PBAT), polybutylene succinate (PBS), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyurethane (PUR), ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC); polypropylene (PP), polyethylene terephthalate (PET), polyurethane (PUR), ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), polyvinyl furanate (PEF), polytrimethylene furanate (PTF), polytrimethyl terephthalate (PTT), styrene-butadiene rubber (SBR), polybutylene terephthalate (PBT), acrylonitrile-butadiene-styrene (ABS), polyamide (PA), aliphatic polycarbonate (APC), and cellulose acetate (CA).

[0024] Bio-based films suitable for sheet assemblies can be formed from the aforementioned bio-based polymers. For example, bio-based films suitable for sheet assemblies can be made from bio-based polycarbonates (such as Mitsubishi Chemical's DURABIO). TM Or Covestro (Germany) Bio-based polycarbonate films formed by EC (e.g., cellulose-based polymers). For example, bio-based films that can be used in sheet assemblies can be based on cellulose polymers such as TREVA. TM Or bio-based copolyesters, such as TRITAN produced by Eastman Chemical Company. TM .

[0025] The paper can be phenolic paper. Paper can be impregnated with up to about 50% resin. Paper can also be impregnated with less than 50% resin (including petroleum-based resins). Other resins that can be used to impregnate paper include melamine, formaldehyde, and phenolic resins.

[0026] The card may further include an upper printed layer 122 and a lower printed layer 130. The upper printed layer 122 and the lower printed layer 130 may be formed of a material capable of being printed thereon with ink to form an imprint on the visible surfaces (e.g., top or front surface) of the upper printed layer 122 and the visible surfaces (e.g., bottom or back surface) of the lower printed layer 130 of the card 102. This imprint may include identification information (e.g., person's name, company name, account number, photograph, image, etc.) or other information. The upper and lower printed layers may be formed of polyethylene terephthalate (PET). The upper and lower printed layers may be formed of a bio-based polycarbonate film. The upper printed layer 122 and the lower printed layer 130 may be formed of a pre-impregnated printed base paper.

[0027] The upper and lower printed layers may include one or more optical features of the card. For example, one or more metal sheet bodies or the like may be included in and / or added to one or more of the upper or lower printed layers to form reflective features, diffraction features, security features, and / or opacity features of the card.

[0028] The card may also include an upper resin-impregnated printable paper layer 124 and a lower resin-impregnated printable layer 128. The bio-based upper and lower resin-impregnated printable paper layers may be opaque, translucent, or transparent. The resin may include bio-based resins. The resin may include petroleum-based resins. For example, the resin may be a resin containing 40%-70% bio-based resin and the remainder petroleum-based resin.

[0029] The card may also include a core layer 126. The core layer may be formed from resin-impregnated paper. The resin may include bio-based resins. The resin may also include petroleum-based resins. For example, the resin may be a resin having 40%-70% bio-based resin and the remainder being petroleum-based resin. The core layer may be formed as a split core layer by providing the core layer as multiple thin layers or sheets. The paper and / or impregnated resin of the core layer may include high-density particles 134 to increase the weight of the card, which may be ideal for higher-end or luxury transaction cards without having to introduce a metal layer within the sheet assembly 100 or card 102. This prevents the sheet assembly 100 and each card 102 from forming, having, or including a conductive layer that conducts ESD or other currents through the sheet assembly 100 or card 102. Alternatively, other layers of the card may have high-density particles disposed within one or more of the paper or resin. Alternatively, no single layer of the card may have high-density particles.

[0030] The high-density particles can be inorganic particles. Inorganic particles 208 may include one or more of bismuth vanadate, one or more metal oxide pigments, or one or more conductive particles (e.g., copper particles, bronze particles, etc.). Although inorganic particles may include metals, metal oxides, or other conductive particles, the inorganic particles may be spaced apart from each other by paper and / or bio-based resins, such that there is no conductive path through the sheet assembly 100 and / or card 102 via the inorganic particles from one edge or any other edge.

[0031] The sheet assembly 100 may extend continuously from a first edge 104 to an opposite second edge 106, and may extend continuously from a third edge 108 (which intersects with the first edge 104 and the second edge 106) to an opposite fourth edge 110 (which intersects with the first edge 104 and the second edge 106). Similarly, each card 102 may extend continuously from a first edge 112 to an opposite second edge 114, and may extend continuously from a third edge 116 (which intersects with the first edge 112 and the second edge 114) to an opposite fourth edge 118 (which intersects with the first edge 112 and the second edge 114). The absence of conductive layers, sheets, cores, or bodies in the sheet assembly 100 and each card 102 prevents the sheet assembly 100 from conducting ESD or other currents from one sheet edge 104, 106, 108, 110 to any other sheet edge 104, 106, 108, 110, and also prevents each card 102 from conducting ESD or other currents from one card edge 112, 114, 116, 118 to any other card edge 112, 114, 116, 118.

[0032] Reference Figure 3According to one embodiment, the card 103 may include an upper transparent overlay 120, a lower transparent overlay 132, an upper printed layer 122, a lower printed layer 130, an upper resin-impregnated printable paper layer 124, a lower resin-impregnated printable paper layer 128, and a core layer 126, as described above for... Figure 2 As described. Card 103 may also include a bio-based upper film 123 between the upper resin-impregnated printable paper layer and the upper printed layer 122. The upper film 123 may be a non-bio-based film. The bio-based upper film may be a bio-based polycarbonate. Card 103 may also include a bio-based lower film 130 between the lower resin-impregnated printable paper layer 128 and the lower printed layer 131. The bio-based lower film may be a bio-based polycarbonate. The lower film 130 may be a non-bio-based film.

[0033] One or more of the bio-based upper film and the bio-based lower film may include metallization, holography, diffraction, refraction, color shift, and / or security features.

[0034] Reference Figure 4 According to one embodiment, card 102 may include an upper transparent overlay 220 and a lower transparent overlay 232. The upper and lower transparent overlays may be formed of a polymer. In another embodiment, the upper and lower transparent overlays may be formed of paper impregnated with a resin. The resin may include a bio-based resin. The resin may also include a petroleum-based resin. For example, the resin may be a resin having 40%-70% bio-based resin and the remainder being a petroleum-based resin. The resin may be a thermosetting resin. The resin may be a thermoplastic resin. The paper may be phenolic paper. The paper may be impregnated with a bio-based resin up to about 50%. The paper may be impregnated with a resin comprising less than about 50% petroleum-based resin. Other resins that can be used to impregnate paper include melamine, formaldehyde, and phenolic resins.

[0035] The card may further include an upper printed layer 222 and a lower printed layer 230. The upper and lower printed layers may be formed of a material capable of being printed with ink to form imprints on the visible surfaces of the upper printed layer (e.g., the top or front surface) and the lower printed layer (e.g., the bottom or back surface) of the card. The imprints may include identification information (e.g., names, company names, account numbers, photographs, images, etc.) or other information. The upper and lower printed layers may be formed of PET. The upper and lower printed layers may be formed of a bio-based polycarbonate film. The upper and lower printed layers may be formed of a pre-impregnated printed underlayer paper. The upper and lower printed layers may be opaque, translucent, or transparent.

[0036] The upper and lower printed layers can be attached to the upper and lower transparent overlays via upper adhesive layer 221 and lower adhesive layer 227, respectively. Alternatively, the card may not include upper and lower adhesive layers, and the transparent overlay can be attached to the printed layers by applying heat and pressure to the card layers during the manufacturing process.

[0037] The card may further include a core layer 226. The core layer may be formed from resin-impregnated paper. The resin may include bio-based resins. The resin may also include petroleum-based resins. For example, the resin may be one that has 40%-70% bio-based resin and the remainder is petroleum-based resin. The core layer may be formed as a split core layer by providing the core layer as multiple thin layers or sheets. The paper and / or impregnated resin of the core layer may include high-density particles 229 to increase the weight of the card, which may be ideal for higher-end or luxury transaction cards without the need to introduce a metal layer within the sheet assembly or card. This prevents the sheet assembly and each card from forming, having, or including a conductive layer that conducts ESD or other currents through the sheet assembly or card. Optionally, other layers of the card may have high-density particles disposed within one or more of the paper or resin. Optionally, no single layer of the card may have high-density particles.

[0038] Reference Figure 5 According to one embodiment, card 203 may include an upper transparent overlay 220 and a lower transparent overlay 232. The upper and lower transparent overlays may be formed of a polymer. In another embodiment, the upper and lower transparent overlays may be formed of paper impregnated with a resin. The resin may include a bio-based resin. The resin may also include a petroleum-based resin. For example, the resin may be a resin having 40%-70% bio-based resin and the remainder being a petroleum-based resin. The resin may be a thermosetting resin. The resin may be a thermoplastic resin. The paper may be phenolic paper. The paper may be impregnated with a bio-based resin up to about 50%. The paper may be impregnated with a resin comprising less than about 50% petroleum-based resin. Other resins that can be used to impregnate paper include melamine, formaldehyde, and phenolic resins. The card may further include an upper film 228, which may be a bio-based film. The bio-based upper film may be attached to the upper transparent overlay by an adhesive 221. The bio-based upper film may be a bio-based polycarbonate. Biological-based top films may also include metallization, holography, diffraction, refraction, color shift, and / or security features. Top films may also be non-biological based films.

[0039] The card may further include a lower film 233, which may be a bio-based film. The bio-based lower film may be attached to the lower transparent overlay via an adhesive layer 227. The bio-based lower film may be a bio-based polycarbonate. The bio-based lower film may also include metallization, holography, diffraction, refraction, color shift, and / or security features.

[0040] The card may further include ink forming a printing layer on one or more of the upper film 228 or the lower film 233. The upper and lower printing layers may be formed of a material capable of being printed thereon with ink to form an imprint on the visible surfaces of the upper printing layer (e.g., the top or front surface) and the lower printing layer (e.g., the bottom or back surface) of the card. This imprint may include identification information (e.g., a person's name, company name, account number, photograph, image, etc.) or other information.

[0041] The card may further include a core layer 226. The core layer may be formed of resin-impregnated paper. The resin may include bio-based resins. The resin may also include petroleum-based resins. For example, the resin may be one that has 40%-70% bio-based resin and the remainder is petroleum-based resin. The core layer may be formed as a split core layer by providing the core layer as multiple thin layers or sheets. The paper and / or impregnated resin of the core layer may include high-density particles 229 to increase the weight of the card, which may be ideal for higher-end or luxury transaction cards without the need to introduce a metal layer within the sheet assembly or card. This prevents the sheet assembly and each card from forming, having, or including a conductive layer that conducts ESD or other currents through the sheet assembly or card. Optionally, other layers of the card may have high-density particles disposed within one or more of the paper or resin. Optionally, no single layer of the card may have high-density particles. The upper film 228 can be attached to the core layer 226 via the adhesive layer 223, while the lower film 233 can be attached to the core layer 226 via the adhesive layer 225.

[0042] Reference Figure 6 According to one embodiment, card 302 may include an upper transparent overlay 320 and a lower transparent overlay 332. The upper and lower transparent overlays may be formed from paper impregnated with a resin. The resin may include a bio-based resin. The resin may also include a petroleum-based resin. For example, the resin may be one having 40%-70% bio-based resin and the remainder being a petroleum-based resin. The resin may be a thermosetting resin. The resin may be a thermoplastic resin. The paper may be phenolic paper. The paper may be impregnated with a bio-based resin up to about 50%. The paper may be impregnated with a resin comprising less than about 50% petroleum-based resin. Other resins that can be used to impregnate paper include melamine, formaldehyde, and phenolic resins.

[0043] The card may further include an upper printed layer 322 and a lower printed layer 330. The upper and lower printed layers may be formed of a material capable of being printed with ink to form imprints on the visible surfaces of the upper printed layer (e.g., the top or front surface) and the lower printed layer (e.g., the bottom or back surface) of the card. The imprints may include identification information (e.g., a person's name, company name, account number, photograph, image, etc.) or other information. The upper and lower printed layers may be formed of PET. The upper and lower printed layers may be formed of a bio-based polycarbonate film. The upper and lower printed layers may be formed of a pre-impregnated printed base paper.

[0044] The upper and lower printed layers may be attached to the upper and lower transparent overlays. In one embodiment, the upper and lower transparent overlays may be attached to the upper and lower printed layers by applying heat and pressure to the card layers during the manufacturing process.

[0045] The card may further include a core layer 326. The core layer may include an upper core layer 325, an intermediate core layer 327, and a lower core layer 329. The core layer may include one or more optical features of the card. For example, one or more metal sheet bodies or the like may be included in and / or added to one or more of the upper, intermediate, and / or lower core layers to form reflective, diffractive, and / or holographic features of the card. As previously mentioned, the core layer may be formed from resin-impregnated paper. The paper and / or impregnated resin of one or more core layers may include high-density particles to increase the weight of the card, which may be ideal for higher-end or luxury transaction cards without the need to introduce a metal layer within the sheet assembly or card. This prevents the sheet assembly and each card from forming, having, or including a conductive layer that conducts ESD or other currents through the sheet assembly or card. Optionally, other layers of the card may have high-density particles disposed within one or more of the paper or resin. Optionally, no single layer of the card may have high-density particles.

[0046] The core layer may include one or more embedded elements 331, such as circuitry or antennas, which are located within one or more core layers, between two core layers, and / or between one or more core layers and a printed layer. In the illustrated embodiment, the embedded elements are disposed within an intermediate core layer. The embedded elements may be represented by radio frequency identification (RFID) antennas, which can be used to receive and / or transmit electromagnetic signals via electromagnetic waves in response to data acquisition (interrogated) of electromagnetic signals by an RFID reader. For example, circuitry embedded elements may be used for contactless or wireless interaction involving cards.

[0047] As described below, before or after cutting cards from the sheet assembly to complete card manufacturing, one or more additional layers, sheets, or devices may be included within the sheet assembly and / or arranged on the sheet. The core layer of the card and sheet assembly can provide a heavier card (which may be ideal for higher-end or deluxe trading cards) without the need to introduce metal layers within the sheet assembly or card. This prevents the sheet assembly and each card from forming, having, or including a conductive layer that conducts ESD or other currents through the sheet assembly or card.

[0048] After the cards are cut from the sheet assembly, one or more inks can be printed, transferred, or otherwise deposited onto the upper and / or lower printed layers. These inks can form text, numbers, images, etc., for identifying the cardholder, financial institution, account, etc. Optionally, the inks can form graphics, etc. Although the inks are shown in the accompanying drawings as a continuous layer extending over the printed layers, alternatively, the inks may cover only a portion of the upper and / or lower printed layers, rather than all of them.

[0049] A clear overlay and / or a lower clear overlay can be printed or deposited on the ink to protect the ink from removal from the upper and / or lower printed layers. For example, a clear overlay can be disposed above and above the upper and / or lower printed layers. This clear overlay can be provided on and above the printed layers by heat and pressure or by an adhesive between the clear overlay and the printed layers.

[0050] Figure 7 A flowchart illustrating a method 500 for forming a sheet assembly according to one embodiment, the sheet assembly being cut into smaller cards. Method 500 may represent operations performed to form a sheet assembly 100 cut into cards 102, 202, 302. At 502, a core layer is formed from paper impregnated with resin. The resin may be a bio-based resin. Bio-based resins may be resins composed of renewable or biological resources. Bio-based resins may include non-petroleum-based resins. Optionally, the paper and / or resin may include high-density particles that may be inorganic particles. Inorganic particles may include one or more of bismuth vanadate, one or more metal oxide pigments, or one or more conductive particles (e.g., copper particles, bronze particles, etc.). The core layer may also be provided with an embedded element, such as an RFID antenna. The core layer may also include one or more layers of paper impregnated with resin.

[0051] At 504, the upper layer is bonded to the core layer. The upper layer can be resin-impregnated paper. The resin can include bio-based resins. It can also include petroleum-based resins. The upper layer can be bonded to the core layer by heat and pressure. The resins in the upper and core layers can react to heat and pressure to self-bond the individual layers together. The upper layer can be formed of PET, bio-based polycarbonate, or a pre-impregnated printing underlayer paper. The upper layer can accept a first printing for a first imprint of one or more cards, as described above. For example, ink can be printed on the upper sheet by a card manufacturer or producer. The upper layer may also have reflective features, diffraction features, security features, and / or opacity features of the card.

[0052] At 506, the lower layer is coupled to the core layer to form a sheet assembly of the upper, core, and lower layers. The lower layer may be coupled to the core layer, wherein the core layer is disposed between the upper and lower layers. The lower layer may be formed of the same material as and similar to the upper layer, and the lower layer may accept a second printing of a second imprint of one or more cards. The lower layer may also have reflective features, diffraction features, security features, and / or opaque features of the card.

[0053] The sheet assembly may have an upper transparent cover layer and a lower transparent cover layer to form a card, which can be cut from the sheet assembly. These transparent cover layers may be a polymer impregnated with resin or paper. The resin may be a petroleum-based resin or a non-biodegradable resin. The transparent upper and lower transparent cover layers may be bonded to the respective upper and lower layers by heat and pressure or by adhesive.

[0054] In one embodiment, a sheet assembly is provided that can be cut into one or more cards. The sheet assembly includes an upper layer configured to receive a first printing of a first imprint of one or more cards. The sheet assembly may also include a core layer coupled to the upper and lower layers, the lower layer being configured to receive a second printing of a second imprint of one or more cards. The lower layer may be coupled to the core layer, wherein the core layer is disposed between the upper and lower sheets. One or more of the upper layer, core layer, or lower layer may be formed of paper impregnated with a resin, including bio-based resins.

[0055] The resin may further include petroleum-based resins.

[0056] The resin can be a bio-based resin with 40%-70% bio-based content.

[0057] One or more of the upper, core, or lower layers of paper or resin may include inorganic particles. These inorganic particles may include bismuth vanadate, one or more metal oxide pigments, or one or more conductive particles. The inorganic particles may include one or more conductive particles, including one or more copper or bronze particles.

[0058] The upper, core, and lower layers may extend continuously from a first edge of the sheet assembly to an opposite second edge of the sheet assembly, and the upper, core, and lower layers may extend continuously from a third edge of the sheet assembly to an opposite fourth edge of the sheet assembly, wherein each of the third and fourth edges extends continuously from the first edge to the second edge. The sheet assembly may not conduct current from any one of the first, second, third, or fourth edges to any one of the first, second, third, or fourth edges.

[0059] The core layer may include a radio frequency identification antenna.

[0060] The core layer may be formed by at least an upper core layer, an intermediate core layer and a lower core layer, wherein the upper core layer is located between the intermediate core layer and the upper core layer, and the lower core layer is located between the intermediate core layer and the lower core layer.

[0061] One or both of the upper or lower core layers may include one or more of the following: reflection features, diffraction features, or holographic features.

[0062] The sheet assembly may further include an inlay disposed on an intermediate core layer located between an upper core layer and a lower core layer, the inlay including a radio frequency identification antenna.

[0063] The sheet assembly further includes a bio-based upper film and a bio-based lower film. The bio-based upper film and the bio-based lower film may be bio-based polycarbonate films. One or more of the bio-based upper film and the bio-based lower film may include one or more of metallization, holography, diffraction, refraction, color shift, or security features.

[0064] Sheet assemblies may not conduct current.

[0065] The card may be formed from sheet components. The card may be one or more of the following: a financial transaction card, an identity card, an access card, a key card, or a security card.

[0066] Sheets can be made from sheet components. Sheets can form one or more of the following: countertops, tabletops, furniture overlays, or flooring.

[0067] In one embodiment, a method for producing a sheet assembly may include: forming a core layer and attaching an upper layer to the core layer, the upper layer being configured to receive a first print of a first mark of one or more cards. The method may include attaching a lower layer to the core layer to form a sheet assembly comprising the upper layer, the core layer, and the lower layer. The lower layer may be attached to the core layer, wherein the core layer is disposed between the upper layer and the lower layer. The lower layer may be configured to receive a second print of a second mark of one or more cards. The sheet assembly may be configured to be cut into one or more cards. One or more of the upper layer, the core layer, or the lower layer may be formed from paper impregnated with a resin, including bio-based resins.

[0068] The resin may further include petroleum-based resins.

[0069] The resin can be a bio-based resin with 40%-70% bio-based content.

[0070] One or more of the upper, core, or lower layers of paper or resin may include inorganic particles. These inorganic particles may include bismuth vanadate, one or more metal oxide pigments, or one or more conductive particles. The inorganic particles may include one or more conductive particles, including one or more copper particles or bronze particles.

[0071] The upper, core, and lower layers extend continuously from a first edge of the sheet assembly to an opposite second edge of the sheet assembly, and extend continuously from a third edge of the sheet assembly to an opposite fourth edge of the sheet assembly, wherein each of the third and fourth edges extends continuously from the first edge to the second edge. The sheet assembly may not conduct current from any of the first, second, third, or fourth edges to any of the first, second, third, or fourth edges.

[0072] The method may include arranging a radio frequency identification antenna in the core layer.

[0073] Forming a core layer may include forming at least an upper core layer and a lower core layer, wherein the upper core layer is located between the lower core layer and the upper layer, and a bottom core layer is located between the upper core layer and the lower layer. One or both of the upper core layer or the lower core layer may include one or more of a reflection feature, a diffraction feature, or a holographic feature.

[0074] Forming the core layer may include forming an upper core layer, a lower core layer, and an insert disposed between the upper and lower core layers. The insert may include a radio frequency identification antenna.

[0075] The method may include providing a bio-based upper film and a bio-based lower film. The bio-based upper film and the bio-based lower film may be bio-based polycarbonate films. One or more of the bio-based upper film and the bio-based lower film may include one or more of metallization, holography, diffraction, refraction, color shift, or security features.

[0076] Sheet assemblies may not conduct current.

[0077] The method may include cutting sheet components to form a card. The card may be one or more of a financial transaction card, identity card, access card, key card, or security card.

[0078] The method may include forming a sheet from a sheet assembly. The sheet may be one or more of a cabinet surface, countertop, furniture overlay, and flooring.

[0079] In one embodiment, a sheet assembly that can be cut into one or more cards is provided. The sheet assembly may include an upper layer and a core layer, wherein the upper layer is configured to receive a first printing of a first imprint of one or more cards, and the core layer is coupled to the upper sheet. The sheet assembly may include a lower layer configured to receive a second printing of a second imprint of one or more cards. The lower layer may be coupled to the core layer, which is disposed between the upper and lower layers. The sheet assembly may include an upper transparent overlay disposed over the upper layer and a lower transparent overlay disposed over the lower layer. One or more of the upper layer, core layer, or lower layer may be formed of paper impregnated with a resin, including a bio-based resin, and the upper and lower transparent overlays may be formed of a polymer or paper impregnated with a resin, including a bio-based resin.

[0080] Resins may also include petroleum-based resins.

[0081] The resin can be a bio-based resin with 40%-70% bio-based content.

[0082] One or more of the upper, core, or lower layers of paper or resin may include inorganic particles. The inorganic particles may include bismuth vanadate, one or more metal oxide pigments, or one or more conductive particles, which may include one or more copper particles or bronze particles.

[0083] The upper, core, and lower layers extend continuously from a first edge of the sheet assembly to an opposite second edge of the sheet assembly, and the upper, core, and lower layers extend continuously from a third edge of the sheet to an opposite fourth edge of the sheet, wherein each of the third and fourth edges extends continuously from the first edge to the second edge. The sheet assembly may not conduct current from any one of the first, second, third, or fourth edges to any one of the first, second, third, or fourth edges.

[0084] The core layer may include a radio frequency identification antenna.

[0085] The core layer may be formed of at least an upper core layer and a lower core layer, wherein the upper core layer is located between the lower core layer and the upper core layer, and the lower core layer is located between the upper core layer and the lower core layer. One or both of the upper core layer or the lower core layer may include one or more of reflection features, diffraction features, or holographic features.

[0086] The sheet assembly may include an insert disposed between an upper core layer and a lower core layer. The insert may include a radio frequency identification antenna.

[0087] The upper layer may include a bio-based upper film and the lower layer may include a bio-based lower film. The bio-based upper film and / or the bio-based lower film may be bio-based polycarbonate films.

[0088] One or more of the bio-based upper film or the bio-based lower film include one or more of the following: metallization, holography, diffraction, refraction, color shift, or security features.

[0089] Sheet assemblies may not conduct current.

[0090] The method may include cutting sheet components to form a card. The card may be one or more of a financial transaction card, identity card, access card, key card, or security card.

[0091] The method may include forming a sheet from a sheet assembly. The sheet may be one or more of a cabinet surface, countertop, furniture overlay, or flooring.

[0092] The singular forms “a,” “an,” and “the” include plural items unless the context clearly indicates otherwise. “Optional” or “optionally” indicates that the event or situation described below may or may not occur, and that the specification may include instances of the event occurring and instances of the event not occurring. Approximate expressions, as used herein and throughout the specification and claims, may be used to modify any quantitative expression that allows for variation without altering its underlying function. Thus, a value modified by one or more terms such as “about,” “substantially,” and “approximately” may not be limited to the specified precise value. In at least some instances, an approximate expression may correspond to the precision of the instrument measuring that value. Scope definitions may be combined and / or interchanged herein and throughout the specification and claims, such scopes may be determined and include all subscopes contained therein, unless the context or expression indicates otherwise.

[0093] The description uses examples to disclose embodiments, including best practices, and enables those skilled in the art to practice these embodiments, including making and using any apparatus or system and performing any of the included methods. The claims define the patentable scope of this disclosure and include other examples that are obvious to those skilled in the art. If some other examples have constituent elements that are not indistinguishable from the wording of the claims or include equivalent structural elements that are not substantially different from the wording of the claims, these other examples are intended to fall within the scope of the claims.

Claims

1. A sheet assembly configured to be cut into one or more cards, the sheet assembly comprising: Upper layer, the upper layer being configured to receive a first print of a first imprint of one or more cards; A core layer, which is connected to the upper layer; as well as The lower layer, configured to receive a second printing of a second imprint from one or more cards, is coupled to the core layer, which is disposed between the upper and lower layers. The upper layer, the core layer, or the lower layer, or one or more thereof, are formed of paper impregnated with resin, including bio-based resins. One or more of the paper or resin in the upper layer, the core layer, or the lower layer comprises high-density inorganic particles, the high-density inorganic particles comprising one or more conductive particles, wherein the inorganic particles are separated from each other by paper and / or bio-based resin such that there is no conductive path through the sheet assembly.

2. The sheet assembly of claim 1, wherein the resin further comprises a petroleum-based resin.

3. The sheet assembly of claim 1 or 2, wherein the resin is a bio-based resin having 40%-70% and the remainder being a petroleum-based resin.

4. The sheet assembly of claim 1, wherein the inorganic particles comprise one or more of bismuth vanadate, metal oxide pigments, copper particles, or bronze particles.

5. The sheet assembly of claim 1, wherein the upper layer, the core layer, and the lower layer extend continuously from a first edge of the sheet assembly to an opposite second edge of the sheet assembly, and the upper layer, the core layer, and the lower layer extend continuously from a third edge of the sheet assembly to an opposite fourth edge of the sheet assembly, wherein each of the third edge and the fourth edge extends continuously from the first edge to the second edge. The sheet assembly wherein current is not conducted from any one of the first edge, the second edge, the third edge, or the fourth edge to any one of the first edge, the second edge, the third edge, or the fourth edge.

6. The sheet assembly of claim 1, wherein the core layer is formed from at least an upper core layer, an intermediate core layer, and a lower core layer, wherein the upper core layer is located between the intermediate core layer and the upper layer, and the lower core layer is located between the intermediate core layer and the lower layer, and one or both of the upper core layer or the lower core layer include one or more of a reflection feature, a diffraction feature, or a holographic feature.

7. The sheet assembly of claim 6, further comprising an insert disposed on the intermediate core layer between the upper core layer and the lower core layer, the insert comprising a radio frequency identification antenna.

8. The sheet assembly of claim 1, further comprising a bio-based upper film and a bio-based lower film.

9. The sheet assembly of claim 8, wherein, The bio-based upper film and the bio-based lower film are bio-based polycarbonate films.

10. The sheet assembly of claim 8, wherein, One or more of the bio-based upper film and the bio-based lower film include safety features.

11. The sheet assembly of claim 8, wherein, One or more of the bio-based upper film and the bio-based lower film include one or more of the following features: metallization, holography, diffraction, refraction, or color shift.

12. The sheet assembly of claim 1, further comprising: An upper transparent overlay layer is disposed above the upper layer; as well as A lower transparent overlay layer disposed above the lower layer, wherein one or more of the upper transparent overlay layer or the lower transparent overlay layer are formed of a bio-based polymer or paper impregnated with a resin, the resin including a bio-based resin.

13. A card made from a sheet assembly as described in any one of claims 1-12, wherein the card is one or more of a financial transaction card, an identity card, a key card, or a security card.

14. A card made from a sheet assembly as described in any one of claims 1-12, wherein the card is an access card.

15. A sheet comprising a sheet assembly as described in any one of claims 1-12, wherein the sheet forms one or more of a cabinet surface, countertop, furniture cover, or floor.

16. A method for forming a sheet assembly, comprising: Forming a core layer; The upper layer is connected to the core layer, and the upper layer is configured to receive a first printing of a first imprint of one or more cards; as well as A lower layer is coupled to the core layer to form a sheet assembly consisting of the upper layer, the core layer, and the lower layer, wherein the lower layer is coupled to the core layer, and wherein the core layer is disposed between the upper layer and the lower layer, and the lower layer is configured to receive a second printing of a second mark of the one or more cards. The sheet assembly is configured to be cut into one or more cards. One or more of the upper layer, the core layer, or the lower layer are formed of paper impregnated with resin, including bio-based resins. One or more of the paper or resin in the upper layer, the core layer, or the lower layer comprises high-density inorganic particles, the high-density inorganic particles comprising one or more conductive particles, wherein the inorganic particles are separated from each other by paper and / or bio-based resin such that there is no conductive path through the sheet assembly.

17. The method of claim 16, wherein the resin further comprises a petroleum-based resin.

18. The method of claim 16 or 17, wherein the resin is 40%-70% bio-based and the remainder is petroleum-based.

19. The method of claim 16, wherein the inorganic particles comprise one or more of bismuth vanadate, metal oxide pigments, copper particles, or bronze particles.

20. The method of claim 16, wherein the upper layer, the core layer, and the lower layer extend continuously from a first edge of the sheet assembly to an opposite second edge of the sheet assembly, and the upper layer, the core layer, and the lower layer extend continuously from a third edge of the sheet assembly to an opposite fourth edge of the sheet assembly, wherein each of the third edge and the fourth edge extends continuously from the first edge to the second edge. The sheet assembly wherein current is not conducted from any one of the first edge, the second edge, the third edge, or the fourth edge to any one of the first edge, the second edge, the third edge, or the fourth edge.

21. The method of claim 16, wherein forming the core layer comprises forming at least an upper core layer and a lower core layer, wherein the upper core layer is located between the lower core layer and the upper layer, and the lower core layer is located between the upper core layer and the lower layer, wherein one or both of the upper core layer or the lower core layer comprises one or more of a reflection feature, a diffraction feature, or a holographic feature.

22. The method of claim 21, wherein forming the core layer includes forming an upper core layer, a lower core layer, and an embedding disposed between the upper core layer and the lower core layer, the embedding comprising a radio frequency identification antenna.

23. The method of claim 22, further comprising disposing a bio-based upper film between the upper layer and the core layer and disposing a bio-based lower film between the core layer and the lower layer, wherein the bio-based upper film and the bio-based lower film are bio-based polycarbonate films.

24. The method of claim 23, wherein one or more of the bio-based upper film and the bio-based lower film include safety features.

25. The method of claim 23, wherein one or more of the bio-based upper film and the bio-based lower film include one or more of metallization, holography, diffraction, refraction, or color shift features.

26. The method of claim 16, further comprising: A transparent overlay layer is provided on top of the upper layer; as well as A lower transparent overlay is provided above the lower layer, wherein one or more of the upper transparent overlay or the lower transparent overlay are formed of a bio-based polymer or paper impregnated with a resin, the resin including bio-based resins.

27. The method of claim 16, further comprising cutting the sheet assembly to form a card, wherein the card is one or more of a financial transaction card, an identity card, a key card, or a security card.

28. The method of claim 16, further comprising cutting the sheet assembly to form a card, wherein the card is an access card.

29. The method of claim 16, further comprising forming a sheet from the sheet assembly, wherein the sheet comprises one or more of a cabinet surface, countertop, furniture cover, or flooring.

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