Transaction and id card with selected texture and color

Abstract

To provide a metal card and / or ceramic card that has a wide range of colors and textures.SOLUTION: The card includes: a specially treated thin decorative layer adhered to a thick core layer made of metal or ceramic materials, where the thin decorative layer is designed to provide a selected color and / or selected texture to the surface of the metal card. The decorative layer includes: (a) an anodized metal layer, or (b) a layer made from plant or animal materials (for example, wood, leather); or (c) a combination of a laser-reactive material (such as carbon powder) mixed with a binder material (such as cement, mortar, epoxy); or (d) a ceramic layer; and (f) a layer of crystalline cloth material. The card may also be a dual-interface smart card that can be read non-contact and / or in contact.SELECTED DRAWING: Figure 1B

Description

Technical Field

[0001] This application claims priority based on a provisional application entitled "Transactions and ID Cards with Controlled Color" having application number 62 / 001,706, filed on May 22, 2014, the teachings of which are incorporated herein by reference. This application also claims priority based on a provisional application entitled "Ceramic Transactions and ID Cards with Controlled Color" having application number 62 / 074,305, filed on November 3, 2014, the teachings of which are incorporated herein by reference.

[0002] The present invention relates to the manufacture of metal cards having various colors and textures. In particular, the present invention relates to an apparatus and method for creating a transaction and ID card or any similar document having a metal layer that can be made to have various colors and textures. The present invention also relates to cards having a core layer of ceramic material and metal cards having a decorative ceramic layer.

Background Art

[0003] In the affluent market, it is desirable to provide metal cards or ceramic cards to give the card owners a sense of affluence and superiority. It is also desirable to provide different colors and textures to metal cards to provide a good appearance, touch, and / or a certain degree of personalization.

[0004] Physical vapor deposition (PVD) is known to be used to color metal transaction cards, but PVD has limitations in its color range and is relatively expensive. PVD also highly depends on the substrate on which it is deposited. PVD is a vacuum process involving high heat and batch operation, and this process requires individual racking and rotation of parts for color uniformity, which is costly. Since this subjects the metal to high temperatures, it may cause the metal to shrink and distort.

[0005] In some metal cards, printed PVC layers or other polymers are used to decorate the outer surface of the card. The use of these polymer layers has undesirable characteristics such as minimum print thickness, weight loss of the metal card due to the thickness of the polymer, and the problem of laminating dissimilar materials. The use of different thicknesses and compounds can also cause warping or bending of the parts due to non-uniform shrinkage during platen lamination.

Summary of the Invention

Problems to be Solved by the Invention

[0006] The object of the present invention is to overcome these and other problems and enable the production of metal cards and / or ceramic cards having a wide range of colors and textures.

Means for Solving the Problems

[0007] The card manufactured according to the present invention includes a specially treated thin decorative layer adhered to one or both sides of a thick core layer of a metal, ceramic-coated metal or polymer, or solid ceramic material, where the thin decorative layer is designed to provide a selected color and / or a selected texture on the surface of the card. The decorative layers used in the practice of the present invention include (a) an anodized metal layer; or (b) a layer of a material derived from a plant or animal substance (e.g., wood, leather); or (c) a combination of a binder material (e.g., cement, mortar, epoxy) mixed with a laser-reactive material (e.g., finely divided carbon); or (d) a ceramic layer; and (e) a layer of a crystalline fabric material. The card may be a dual-interface smart card that can be read in a non-contact and / or contact manner.

[0008] The production of the metal card according to the present invention generally includes the preparation and treatment of a thin decorative layer and the adhesion of the decorative layer to a thick metal substrate, where the thin decorative layer is designed to provide a selected color and / or a selected texture mainly on the front surface of the metal card, but can also be provided on the back surface of the card.

[0009] When the thin decorative layer is an anodized metal layer, the metal layer is prepared and processed to have the color selected for imparting color to the card. For several reasons, color imparting (coloring) to the metal layer by anodization is preferred over PVD treatment. Anodization is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant anodic oxide finish. Therefore, coloring the metal by anodization is highly desirable. Aluminum is ideally suited for anodization. However, the present invention can be practiced using other non-ferrous metals, such as magnesium, titanium, zinc, niobium, tantalum, or any other metal.

[0010] In the case of an aluminum film, for example, the anodic oxide structure is derived from the aluminum substrate and is composed entirely of aluminum oxide throughout. This aluminum oxide is not applied to the surface like paint or plating, but is completely integrated with the underlying aluminum substrate, so it will not chip or peel off. It has a highly ordered porous structure that enables secondary processes such as coloring and sealing.

[0011] Anodization can be carried out by immersing aluminum in an acid electrolytic bath (tank) and passing an electric current through the medium. A cathode is attached inside the anodizing tank. Aluminum acts as the anode, so oxygen ions are released from the electrolyte and combine with the aluminum atoms on the surface of the part to be anodized. Therefore, anodization is a highly controlled oxidation event and an enhancement of a natural phenomenon. Color can be introduced by passing the anodized foil through a dye bath of the appropriate (desired) color and then through a sealer bath.

[0012] Using a colored anodic layer on the metal layer provides greater flexibility and cost reduction. Replacing the polymer material with a printed anodic material overcomes these issues because the metal is denser than the polymer and has no minimum printing thickness limitation. This composition and method can be used in all types of transaction and ID cards, including non-contact, contact, and dual interface smart cards.

[0013] In the present invention, the color and / or texture of the anodized layer can be further modified by (a) dyeing the anodized layer in a single color or multiple colors, or (b) printing graphics using techniques such as screen printing, sublimation printing, or any digital printing system. The anodized metal layer can also be further modified by techniques such as laser engraving, mechanical engraving, die cutting, or embossing. The anodized metal layer can be used on the card as a full-surface material (i.e., extending over the entire length and width of the card), a patch, a stripe, or other decorative designs. The anodized metal may be laser marked or otherwise engraved or marked and electroplated with a base metal or a noble metal on the anodized surface in a selective pattern or flood coating.

[0014] In one aspect of the present invention, imparting color to a multi-layer metal card is achieved by using at least one anodized colored metal layer and selectively modifying other layers, which may or may not be colored, to provide the desired aesthetic and / or functional effects.

[0015] When the decorative layer is a layer of a material derived from plant matter (e.g., wood), special care must be taken to process the decorative layer so as to maintain the original (unique) pattern and texture before and during its adhesion to the metal substrate. As used herein, texture refers to the visual and especially tactile qualities of the surface. This includes the feel, touch, appearance, and granularity of the surface.

[0016] Similarly, when the decorative layer is a layer of a material derived from animal matter (e.g., leather), a special process had to be developed to process the decorative layer so as to maintain the original (unique) pattern and texture before and during its adhesion to the metal substrate.

[0017] Also, when the decorative layer is a layer of a material derived from various aggregate binder materials (e.g., cement, mortar, epoxy) mixed with a laser-reactive material (e.g., micronized carbon), a special configuration is created to produce a card having an upper surface with a desired color and texture.

[0018] Also, various ceramic materials having a selected texture and color can be used to form a decorative layer adhered to a metal substrate.

[0019] Accordingly, the thin decorative layer may be a veneer layer of a natural and / or non-metallic textured material that is prepared and processed to provide a unique and / or selected texture to the card surface.

[0020] The card embodying the present invention includes a thin decorative layer and a thick core layer of metal, ceramic-coated metal, ceramic-coated polymer, or solid ceramic material. Further, the card can include a number of different polymer layers. Additionally, the metal card embodying the present invention can include an integrated circuit chip and an antenna that enable RF transmission of signals between the card and a card reader. These cards are "smart" cards that can also function as contact cards and / or dual interfaces (contact and / or non-contact).

[0021] Further, the card embodying the present invention includes a pocket formed on the upper surface of the card that enables one or more decorative layers to be placed therein.

Brief Description of the Drawings

[0022] In the accompanying drawings, which are not drawn to scale, like reference numerals indicate like components.

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【Figure A cross-sectional view of a card having a colored anodized aluminum foil adhered to a metal substrate according to the present invention. ​ A diagram showing some of the steps of a process for forming a card according to the present invention. ​ A cross-sectional view showing the formation of a pattern in the anodized aluminum layer of FIG. 13A. ​ A cross-sectional view showing the result of electroplating the pattern formed in the anodized aluminum layer of FIG. 13A using a noble metal. ​Cross-sectional view of a card having a ceramic core and a decorative layer. ​ Isometric top view of a pocket formed in a ceramic core layer. ​ Isometric plan view of a decorative layer adhered to the pocket of FIG. 14A. **DETAILED DESCRIPTION OF THE INVENTION**

[0023] A metal card having at least one anodized layer FIG. 1 shows one embodiment of a transaction card 10 of a metal body having a number of different colored layers. In FIG. 1, the card 10 includes a colored hard coat top layer 12 overlying an anodized aluminum foil layer 14. The hard coat layer 12 can be adhered to the anodized layer 14 by any known or suitable method (e.g., by bonding, spraying thereon and curing, or by adhering via an adhesive layer or carrier layer, or by being transferred from a carrier sheet). The layer 14 is adhered to a base metal layer 16 via an adhesive layer 15. The layers 12 and 14 are designed to have selected colors used to give the card 10 different colors and a decorative appearance. Combining the colors of the layers 12 and 14 with the color of the base metal layer 16 can provide a wider range of colors and decorative patterns for the card.

[0024] In the manufacture of the card, the thickness of the hard coat layer 12 is typically 2 to 50 microns, the thickness of the aluminum foil layer 14 is in the range of 0.0005 to 0.014 inches, and the thickness of the metal layer 16 is in the range of 0.005 to 0.032 inches. Note that the layer 12 is optional and the layer 14 is primarily intended to provide a decorative (coloring) function.

[0025] Layer 12 provides a scratch-resistant surface and can also provide a coloring layer. The hard coat layer 12 can be formed from nanoparticles such as silicate nanoparticles, zinc oxide nanoparticles, silicon dioxide crystalline nanoparticles, or any other suitable nanoparticles having a suitable carrier such as a solvent, aqueous, or UV curable acrylate, vinyl, urethane, etc. The hard coat can be applied by coating techniques such as spraying, gravure, reverse roll, direct roll, slot coating, etc.

[0026] The hard coat layer 12 can be applied to a card or a subassembly used in forming a card using a special carrier layer. This special carrier enables the release layer and the hard coat layer to be adhered to the special carrier layer to form a subassembly, and then the subassembly can be attached and transferred to another subassembly to form an intermediate assembly, from which the carrier and the release layer can be removed, leaving the hard coat layer as the upper and / or lower layer of the card. The hard coat layer may be transparent or colored. Color is added to the hard coat layer by adding a pigment or dye to the adhesive layer or by mixing it with the hard coat vehicle itself.

[0027] The second layer 14 consists of a colored anodic metal layer shown to be adhered to the base metal layer 16 via an adhesive layer 15. This layer 14 can also be bonded and laminated to the underlying layer 16. The anodized metal layer 14 is shown to be made of aluminum. However, the anodized layer 14 may be titanium, zinc, niobium, tantalum, or any other metal that can be anodized. In the present invention, the anodized layer can be further modified by (a) dyeing the anodized layer in a single color or multiple colors, or (b) printing graphics via techniques such as screen printing, sublimation printing, or any digital printing system. The anodized metal layer 14 can be further modified by techniques such as laser engraving, mechanical engraving, die cutting, or embossing. The anodized metal layer can be used on the card as a full-surface material (i.e., extending over the entire length and width of the card), a patch, a stripe, or other decorative designs.

[0028] Using a colored anode layer 14 instead of a polymer layer on the colored metal layer 16 results in higher flexibility and cost reduction. Using a printed anodic material instead of a polymer material overcomes the problems that exist when using a polymer because the metal is denser than the polymer and has no minimum printing thickness limitation. This composition and method can be used in all types of transaction and ID cards, including non-contact, contact, and dual-interface smart cards.

[0029] The base or substrate metal layer 16 used in the card embodying the present invention may be stainless steel, bronze, copper, titanium, or any suitable metal that gives the majority of the weight to the card's body (structure).

[0030] Layers 12, 14, 15, and 16 can be combined in one or more lamination steps using heat, pressure, and / or UV curing. FIGS. 1, 1A, and 1B show the construction of a multi-layer metal transaction card, where basically the entire card is made of metal and its color can be controlled. The signature panel and magnetic stripe (not shown) are adhered (directly or indirectly through a polymer layer) below the metal layer 15 shown in FIGS. 1, 1A, and 1B to form a complete transaction card.

[0031] In FIGS. 1, 1A, and 1B, a laser 101 for irradiating the card 10 with a laser beam is shown. The output level of the laser 10 is controlled by a power controller 103. By controlling the output level of the laser, it becomes possible to manufacture a card whose color can be changed and controlled. The laser can be used to melt and remove selected portions of the hard coat layer 12 and the anodized layer 14. Further, by using the laser to control (vary) the output level and polarization of the laser (for example, this may be called a kind of diffractive laser), the color of the base metal layer 16 can be changed. Thus, the color and texture of each card can be controlled and changed.

[0032] FIG. 1A shows that by selectively laser melting or engraving the upper layer 12 to expose the second layer 14, a desired color contrast can be generated. This can be achieved by individual optimized laser parameters or engraving techniques.

[0033] FIG. 1B shows that a second set of parameters can be used to remove selected portions of the anodic layer 14 that expose the base metal 16 below it. This enables a multi-color gradient on the metal card, which may include the base metal finish itself. This aesthetic appearance is highly desirable in the market.

[0034] Note that only a single anodized layer is shown in the figure. However, it would also be possible to use two or more (i.e., multiple) anodized and suitable metal layers. For example, since there is one anodized layer per piece of aluminum, it would be possible to include multiple aluminum layers.

[0035] Hybrid metal-polymer card Figure 2 is a cross-sectional view of card 10 including the colored layer shown in Figure 1, and further includes a polymer layer 18 adhered to the underside of the metal layer 16 by an adhesive layer 17. The assembly consisting of layers 12, 14, 15, 18, 17, and 18 can be laminated to produce a "hybrid" card that includes a combination of a metal layer and at least one polymer layer. The polymer layer 18 can be of any suitable material (e.g., PVC, PC, PET, etc.). The polymer layer 18 can include a magnetic stripe and a signature panel. Alternatively, a magnetic stripe and a signature panel can be added after the card is separated from the sheet on which the multi-card is formed.

[0036] Wireless, contact, or dual interface card FIG. 3 is a cross-sectional view of a hybrid dual-interface metallic smart card having a colored layer embodying the present invention, and FIG. 4 is an exploded view of the layers and components of a card of the type shown in FIG. 3 (adhesive layers being omitted). FIGS. 3 and 4 show that a card of a selected texture and color embodying the present invention can be made to include all the components necessary to make each card a “smart” card. As shown in FIGS. 3 and 4, a “smart” card is made to include an integrated circuit module 109 that includes an integrated circuit (IC) 110 (a semiconductor processor chip or microchip) and an RF (radio / contactless) transmission module antenna 112. Module 109 and its IC 110 can also include contacts (116, 118) that extend to the periphery of the card and along the surface of the card for contact with a reader. Module 109 and its IC 110 can be used as part of the contactless (radio) system of FIG. 1, and / or as a direct contact system, and / or as a dual-interface (contact and / or contactless) system. In FIG. 3, card 10 includes a ferrite layer 20 adhered to the underside of a metal layer 16 via an adhesive layer 19. A booster antenna formed on or in layer 22 is located between ferrite layer 20 and polymer layer 18. Ferrite layer 20 is introduced to enable RF transmission between a card reader (not shown) and chip 110 such that metal layer 16 does not attenuate input and output RF signals. There is a cutout in the upper layer of the card to accommodate module 109. Polymer layer 18 can include a magnetic stripe and signature panel, or additional layer 24 can be adhered to layer 18 to provide these functions. The addition of a colored hard coat layer 12 and an anodized metal layer 14 allows a “smart” dual-interface metal-hybrid card formed as shown in FIGS. 3 and 4 to be made to have the desired color and texture characteristics and also to function as any ordinary smart hybrid or metallic card.

[0037] Figures 5 and 5A are cross-sectional views of a card similar to the card shown in Figure 2, but which further includes an embossable copolymer layer 24 (identified in the figure as a polyester layer) formed over an anodized aluminum film layer 14. The card 10 can be formed, as shown in Figure 5, by assembling the layers 12, 24, 14, 16, and 18 and adhering these layers by bonding and / or by using adhesive layers 15, 17, 23. Next, the assembly can be laminated, embossed by an embossing method, and plates 55a, 55b can be laminated to generate an embossed image on the upper layer, or on top of the other upper layers 24 and 14, as shown in Figure 5 (layer 12 is optional and may not be used for all cards). Thus, Figures 5 and 5A show a method of controlling and modifying the color and texture of a card by embossing.

[0038] Alternatively, the embossed layer 24 may be a curable polymer and an adhesive layer may then be adhered. The hard coat layer 12 can be disposed over the embossed layer either before or after the embossing process. During lamination, the embossing plate 55a can also be used for embossing a desired image into the copolyester layer 24 (layer 24 can be any embossable polymer) and the underlying anodized metal layer 14. The copolyester layer 24 (as well as the hard coat layer) provides a scratch-resistant layer and the embossing provides a tactile component desirable in the industry. That is, the embossed surface can give the card a textured feel. The hard coat layer 12 provides additional protection over the polyester and its carrier provides release from the embossing plate.

[0039] FIG. 6 is a top view and FIG. 6A is a cross-sectional view of a metal transaction card that can exhibit four different colors and various graphic and textural features. By way of example, the upper layer 12 may be a black hard coat layer that can provide a background that is more scratch-resistant and less expensive than PVD. The second layer 14 of anodized aluminum adhered to layer 12 may be colored pink. The third metal layer 16 adhered to layer 14 is colored gray. Typically, the fourth layer 161, which is made of a thin plastic (although it could be a metal layer), adhered to layer 16 is colored silver. A laser light source 101 can be used to create a textured and color-controlled card. A first set of laser settings removes selected portions of the hard coat layer 12 to expose the underlying anodized layer. In this example, this is pink and can be used for text and graphics. A second laser setting removes portions of the pink anodized aluminum layer 14 to create the gray features of the metal layer 16. A third laser setting removes portions of the gray metal layer to create the silver features of layer 161. Intermediate gradients can be created by partially removing each layer. This opens up various aesthetic and textural possibilities for metal transaction cards that were not previously possible.

[0040] FIG. 6B shows that the anodized layer 14 can be formed to include many different colored sub-layers (141, 142, 143, 144). That is, layer 14 is a multi-color layer. During the anodizing process, different colors can be introduced into different sub-segments (sub-layers) of the aluminum layer. The different colors can be displayed by laser machining the different sub-layers of layer 14 downward to display different color levels. Instead of laser machining, various colors can be displayed by mechanical engraving or other material removal means. Additional layers may also be colored hard coat layers alone or in combination with metal layers.

[0041] As described above, the card embodying the present invention can be formed, as shown in FIGS. 1, 2, 3, 5, and 6, by first assembling a selected polymer layer and a metal layer and bonding or adhering them with an adhesive. The various layers are generally laminated at a temperature in the range of 200°F to 500°F and an effective pressure of 50 to 500 PSIA. Typically, a first set of optimized laser or mechanical engraving parameters is used to remove the colored transfer hard coat (e.g., 12), and the underlying colored anodized layer is shown. Next, a second set of optimized laser or mechanical engraving parameters is used to remove a portion of the colored anodized layer (14) to expose the metal thereunder. In the case of FIGS. 6 and 6A, a third set of optimized laser or mechanical engraving parameters can be used to expose another colored layer (161). The various layers may be mechanically engraved through the anodized metal into the body of the card, typically stainless steel. As a final step in creating the card, the card is cut to the appropriate size and final processing such as hot stamping is completed.

[0042] Accordingly, the anodized aluminum layer is used as a thin decorative layer (see DLa, DLb in FIG. 11). In one aspect of the present invention, the thin decorative layer includes at least one anodized metal layer to add color and / or texture to the card. The card can also include additional layers of different colors, which can be assembled and laminated with the anodized metal layer to form a multi-layer card. The card can be processed (e.g., laser processed) to produce cards with different colors and textures. By applying various controlled laser output devices (or any similar functional devices) to the laminated card to remove selected portions of different layers, the displayed color, pattern, and texture of the card can be modified.

[0043] In the manufacture of the card embodying the present invention, for commercial and aesthetic reasons, it is important to manufacture a metal card having a specific texture and color and to maintain that texture and color. As already discussed and described above, the metal card embodying the present invention can be formed to include a core metal layer 16 having a decorative layer (e.g., 14 or DLa in FIG. 11) thereon. Alternatively, the decorative layer (e.g., DLa, DLb in FIG. 11) may be formed on and under the core metal layer 16, or only under the core metal layer.

[0044] Card with decorative panel FIG. 7 shows the manufacture of a "textured" metal card having a thin decorative layer selected to be an actual wood layer disposed on the upper surface of the card. It should be noted that the use of "wood" is merely illustrative and is meant to include any material derived from a (living) plant having properties similar to wood. The use of a wood layer (or similar material) is aesthetically important because it has unique properties. That is, the grain and appearance of an actual piece of wood are virtually impossible to replicate and represent a high level of individuality. However, there are important problems in maintaining the texture and appearance of the actual wood layer used to form the card. These are overcome in the manufacture of the card according to the present invention.

[0045] Referring to FIG. 7, the following procedure or steps can be used. 1. As shown in FIG. 7A, a decorative panel layer 700 of natural wood with a low lignin content is selected. By using a wood layer with a low lignin content, it becomes easier to maintain the appearance of the wood layer through various lamination and processing steps for forming the card.

[0046] 2. As shown in FIG. 7B, the wood layer 700 having an upper surface 701 and a bottom surface 703 is pretreated. a. The back surface 703 of the wood layer 700 is sanded until the wood layer has the desired thickness. The range of the wood decorative panel and all other decorative panels may be in the range of 0.001 inch to 0.014 inch. b. Apply an oil film 711 such as linseed oil to the upper surface 701 of the wood layer 700. The oil film 711 ensures that when the wood is laminated, the moisture contained in the wood layer and its overall appearance are maintained. It has been found that applying a thin oil film (e.g., linseed oil) is very important for maintaining the wood layer in good condition throughout the lamination process. The oil replaces the water in the wood structure with a material of a higher boiling point.

[0047] 3. As shown in FIG. 7C, form an assembly 750 that includes a treated wood layer 700 adhered to a metal substrate 16 using an adhesive 15a. The adhesive layer 15a may comprise an acid-modified polyolefin or any suitable adhesive. Typically, layer 700 will have a thickness in the range of 0.001 inches to 0.014 inches, and the metal layer 16 will have a thickness in the range of 0.005 inches to 0.032 inches.

[0048] 4. Use platens 75a and / or 75b to laminate the assembly 750 as shown in FIG. 7D.

[0049] 5. Note that platens 75a and / or 75b may also include an embossing plate (not shown) that allows the assembly 750 to be embossed and laminated simultaneously.

[0050] 6. Chamfer the wood layer 700 as shown in FIG. 7E by cutting off (right-angled edges or corners) to create symmetrically inclined edges and minimize the problem of the edges of the card being frayed or peeled off.

[0051] Card with cement decorative board FIG. 8 shows the manufacture of a "textured" metal card having a thin decorative layer selected to be the aggregate binder material veneer layer 800. The aggregate binder material may be cement, mortar, epoxy, and additives mixed with a laser-reactive material such as micronized carbon or a commercially available laser additive. In FIG. 8a, the laser 800 is shown to be a cement layer mixed with a carbon material. However, as noted above, the cement may be of any of the other materials mentioned. The use of a cement layer provides a unique tactile feel. However, there are significant problems in producing a card having a particular texture and color, maintaining the texture, and providing an image having a high level of contrast. These are overcome in the manufacture of these cards according to the present invention.

[0052] Referring to FIG. 8, the following operations or steps can be used to process the aggregate binder material (e.g., cement) and enhance the color contrast of the processed card.

[0053] 1. As shown in FIG. 8A, form the cement layer 800 from a cement mixture to which a carbon material (e.g., carbon soot) has been added to produce a grayish-colored cement layer 800. 2. Polish the top and / or bottom surfaces (801, 803) of layer 800 to produce a layer having a desired thickness typically in the range of 0.001 inches to 0.010 inches. 3. As shown in FIG. 8B, laser irradiate the cement layer using a laser device 101 to produce a desired pattern (region 804). The laser 101 vaporizes the carbon particles in the selected region, producing a white pattern contrasting with the gray background. 4. Next, the laser-irradiated cement layer 800 can be adhered to the metal substrate 16 via a suitable adhesive layer 15b to form an assembly 850 as shown in FIG. 8C. 5. Instead of step 3 above, the non-laser-irradiated cement layer 800 can first be adhered to the metal substrate 16 and then laser irradiated. 6. FIG. 8D shows that layer 800a can be formed using an epoxy material mixed with carbon particles. Layer 800a can be adhered directly to the metal substrate 16. Layer 800a can be subjected to laser irradiation before or after being adhered to the metal substrate 16. The use of the epoxy material eliminates the need for an additional adhesive layer and provides a very strong bond between the epoxy layer 800a and the underlying metal substrate 16, which may be, for example, steel or other suitable metal.

[0054] Card with leather veneer FIG. 9 shows the manufacture of a "textured" metal card having a thin decorative layer selected to be like an actual leather veneer layer disposed on the upper surface of the card. Note that instead, a similar animal-derived material may be used. As in the case of a "natural" or "actual" wood layer, the use of an actual leather layer is important because it has many unique properties. That is, the grain and richness of the appearance and the pattern exhibited by the actual leather layer are virtually impossible to replicate and represent a high degree of individuality. However, there are important issues in maintaining the texture and appearance of the "natural" leather layer used to form the card. These are overcome in the manufacture of the card according to the present invention.

[0055] Referring to FIG. 9, the following operations or steps can be used to form the card. 1. As shown in FIG. 9, there is a selection step. That is, a natural leather layer 900 having a natural unique pattern on its upper surface 901 is selected. 2. Next, there is leather processing or treatment to prepare the back surface 903 of the leather layer 900, so that the leather layer has a desired thickness and the bottom surface is adapted to receive an adhesive. The typical thickness would be in the range of 0.003 to 0.014 inches. However, this can be made thinner or thicker. 3. Next, as shown in FIG. 9B, there is an embossing step. A desired pattern is embossed on the upper surface 901 of the first leather layer 900. 4. A very novel feature used to laminate the leather layer 900 onto the underlying metal substrate 16 also enables the generation of a mirror image of the embossed pattern. It is extremely important that the lamination process for fixing the embossed leather layer 900 to the underlying metal substrate 16 maintains all the fine features of the leather 900 layer as well as the embossed pattern. This is achieved as follows. The assembly 910 is formed as shown in FIG. 9C, which is a. including an embossed first leather layer 900 adhered to the metal substrate layer 16 via an adhesive layer 15c, and b. a blank (non-embossed) leather layer 902 (i.e., the second leather layer) having an upper surface facing the embossed surface 901 of the first leather layer 900 is shown between the embossed leather layer 900 and the platen 75a. Layer 902 may be the same as layer 900 or may be a similar leather-like material. Layer 902 is selected to have the same or a similar texture as layer 900.

[0056] 5. As shown in FIG. 9D, the assembly 910 undergoes a lamination process. Due to the appropriate selection of layers 900 and 902 (and appropriate lamination pressure), the lamination process maintains the embossed features and patterns in the first leather layer 900 as they are, producing an assembly or sub-assembly 950 as shown in FIG. 9E.

[0057] 6. At the same time, the embossed pattern is transferred (as a mirror image) to the upper surface 911 of the second leather layer 902, which can then be used to emboss subsequent leather layers or similar layers as shown in FIG. 9E. This is important in that the "non-embossed" leather layer (e.g., 902) serves as a template for the production of the next series of cards. This creates successive generations.

[0058] Card with Pocket for Decorative Layer / Patch The edges of the decorative panel layer may be subject to abrasion and peeling. One approach to avoid this problem is to chamfer the edges of the decorative panel layer as shown in Figure 7E. Another approach is to form a pocket 981 on the upper surface of the metal card as shown in Figure 10. Figure 10A is a top view of the card having a cutout 981 for forming a pocket on the upper surface of the card. The pocket can be formed using any known technique. The edges d1 and d2 may range from 0.01 to 1.125 inches, may be non-uniform, or may form an aesthetic pattern. Figure 10B is a cross-sectional view showing that the anodized aluminum layer 14 or any decorative panel layer (e.g., 700, 800, 900) can be adhered to the inner upper surface of the pocket 981 of the card cut out from the core metal layer 16 via a suitable adhesive 15c. This configuration is excellent and prevents the edges of the anodized layer or the decorative panel layer from being abraded, worn, or peeled off.

[0059] Figure 10C shows that a polymer layer, an aluminum layer, or a ceramic layer can be adhered to the lower side of the metal substrate.

[0060] Figure 10D is an isometric plan view of the metal layer 18 in which a pocket 981 is formed. For illustration purposes, it is shown that the pockets are not symmetrically arranged. The pocket 981 can be a small or large portion of the card surface having regular or irregular boundary lines. Figure 10E shows that any decorative layer (DL) can be adhered to the pocket 981 or formed within the pocket 981. This includes an anodized aluminum layer, the various decorative panel layers described above, as well as other decorative decorative panel layers or materials. This includes, by way of example, products currently commercially available called Swarovski Elements Crystal Fabric. This material includes a carrier material completely covered with millions of small cut round crystals. This is elastic, tear-resistant, and extremely light. Since this carrier material features a low-temperature characteristic adhesive, it can be applied to various surfaces by low-temperature heating. This adhesive can be replaced with a stronger adhesive for more demanding environments.

[0061] In other embodiments of the present invention, in order to include decorative materials therein, small pockets in a very limited area having substantially any shape (e.g., a small portion of the surface area of the card) can be formed within the card.

[0062] The above is for illustration purposes. Generally in the present invention, various methods and apparatuses are shown for treating a thin anodized metal layer for attachment to a thick metal substrate and / or a selected thin veneer layer for manufacturing a card having desired color and texture characteristics.

[0063] The metal card embodying the present invention as shown in FIG. 11 can be formed to include the metal layer 16 such that it has a decorative layer (DLa) on the core metal layer 16 and a decorative layer (DLb) under the metal layer. Each of the decorative layers DLa and DLb may be (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, or (f) a layer of a crystalline cloth material. That is, one decorative layer (e.g., DLa) can be any one of the layers specified in a to f above, and the other decorative layer (e.g., DLb) can be DLa or a different one of the layers specified in a to f.

[0064] In FIG. 11A, the leather layer 900 is adhered to one side (the upper surface in the figure) of the metal substrate 16 via an adhesive 15c, and the anodized aluminum layer 14 is adhered to the opposite side (the bottom surface in the figure) of the metal substrate. In this figure (and in FIGS. 11B and 11C below), one type of thin decorative layer (e.g., leather) is adhered to the upper part of the metal substrate, and a different thin decorative layer (e.g., anodized aluminum) is adhered to the bottom surface of the metal substrate.

[0065] In FIG. 11B, the leather layer 900 is adhered to one side (the upper surface) of the metal substrate 16 via an adhesive 15c, and the ceramic veneer layer 990 is adhered to the opposite side (the bottom surface) of the metal substrate.

[0066] In FIG. 11C, the anodized aluminum foil 14a is adhered to one side (upper surface) of the metal substrate 16 via the adhesive 15, and the ceramic decorative panel layer 990 is adhered to the opposite side (bottom surface) of the metal substrate. The signature panel 123 and the magnetic stripe 125 are shown adhered to the ceramic layer 990.

[0067] FIGS. 11B and 11C show that the decorative panel layer may be a layer of ceramic material 990. The ceramic material is made to have substantially all colors and has highly desirable properties since it can be adhered (bonded) to the metal substrate without using an adhesive. The layer of ceramic material can be applied (e.g., sprayed) directly onto the metal substrate 16 and then fired or cured thereon. Further, FIGS. 11B and 11C show that one of the decorative layers may be a decorative panel layer of one type (leather, anodized aluminum), and the other decorative layer may be of a different type (e.g., ceramic).

[0068] FIG. 11D shows that the metal substrate 16 can have a decorative layer DLa adhered to its upper surface and a ceramic layer 990a, and a decorative layer DLb adhered to its bottom surface and a ceramic layer 990b. Due to the wide variety of different colors and textures available for the decorative layer and the ceramic layer, cards having a very wide range of colors and textures can be created.

[0069] FIG. 11E shows a laser light source 101 that can be used to laser engrave a decorative ceramic layer 990a adhered to the upper surface of a metal substrate 16 having a similar or different decorative layer DLb adhered to the bottom surface of the layer 16. The ceramic layer 990a can also be modified using mechanical or chemical engraving, inkjet printing, laser marking, and other methods known in the art to provide the desired aesthetic effect.

[0070] FIG. 11F shows a metal substrate 16 having an anodized aluminum foil 14a adhered to its upper surface and an anodized aluminum foil 14b adhered to its bottom surface. The foils 14a and 14b may have different colors, thicknesses, and shapes.

[0071] FIG. 12 is a cross-sectional view of a metal card showing a structure similar to that of FIG. 11F. This card has an anodized aluminum layer 14a adhered via an adhesive 15 to one side (the upper surface in the figure) of the metal substrate 16, and another anodized aluminum layer 14b adhered via an adhesive 17 to the opposite side (the bottom surface in the figure) of the metal substrate. The anodized layers 14a and 14b are decorative layers adhered to the metal layer 16. A polymer layer 121 is shown adhered to the bottom surface of layer 14b. As shown in FIG. 12A, the layer 121 may be a transparent polymer layer so that the color and decorative features of layer 14b can be seen. A signature panel 123 and a magnetic stripe 125 are formed on the surface of layer 121.

[0072] The use of layer 121 is optional. As shown in FIG. 12B, the bottom layer of the card may be layer 14b (i.e., the polymer layer is not used). In certain embodiments, the applicant has used a thermosetting type of adhesive to directly adhere the signature panel 123 and the magnetic stripe 125 to the anodized aluminum layer 14b.

[0073] FIG. 13A shows the color and decorative features of a card embodying the present invention. In FIG. 13A, the upper anodized layer 14a has an upper region 141 colored blue as an example. The thickness of the region 141 can range from less than 0.1 micron to more than 5 microns. (However, it should be understood that there is a wide variation in this). The layer 14a is adhered to the core metal substrate 16 via an adhesive layer 15, which is then adhered to a decorative layer DLb via an adhesive 17, and the decorative layer DLb may be any layer of the types (a)-(f) described above.

[0074] As shown in FIG. 13B, after the layer shown in FIG. 13A is assembled (see square 1041), a pattern can be formed by removing a selected portion of the anode material in region 141 (see square 1042) and leaving the underlying uncolored aluminum foil. That is, it is a portion of layer 14 or 14a below region 141. Removal of the material in region 141 can be performed by a laser or any other suitable means. For example, when a laser is used, the laser simply removes the material in layer 141 until it passes through layer 141, exposing the remaining layer 141. This is shown in FIG. 13C, which shows a pattern limited to the removal of selected portions of the blue material in region 141. Next, the laser-irradiated assembly can be subjected to an electroplating process (see square 1043) using a metal such as gold or any suitable metal to electroplate a selected metal on or within the pattern formed in the anode region 141. The pattern formed can have the appearance shown in FIG. 13D. As shown in square 1044, the card can be further processed (completed) to include any and all additional features for forming all types of cards as described above.

[0075] Ceramic card FIG. 14 shows that the card 10a can be formed using a ceramic core 131 that can be designed to provide a predetermined color. The decorative layer DLa can be adhered to the upper side of the ceramic core, and / or another decorative layer DLb can be adhered to the lower side of the core layer. The decorative layer DLa may be the same as the decorative layer DLb. However, they do not have to be the same. FIG. 14A shows that a pocket 981 can be formed in the ceramic layer for the placement of the decorative layer (DL) therein as shown in FIG. 14B. The decorative layer may be any layer of the type described above or any other suitable material. The ceramic material is an inorganic non-metallic material made from a compound of metal and non-metal. The ceramic material can be crystalline or partially crystalline. These are formed by the action of heat and subsequent cooling. The ceramic material tends to be strong, hard, brittle, chemically inert, and a non-conductor of heat and electricity.

[0076] For the same reasons that it is desirable to use a metal card, it is desirable to use a ceramic card. In the modern transaction card market, it is often desirable to obtain a "premium" feel, appearance, or tactile function for sale in the affluent market. These transaction cards can be used as debit cards, credit cards, or prepaid cards. As part of this premium feel, a card that is heavier than a standard plastic card is often desirable, and also the durability of the card body is improved. To achieve these desired effects, several card configurations that utilize the above-described ceramic components, including exemplary embodiments in the form of solid ceramic cards, cards containing ceramic inserts, and cards utilizing ceramic coatings, are described herein.

[0077] The solid ceramic card can be made by injection molding it into a desired shape and then sintering it to create a standard size of nominal dimensions (3.37 inches × 2.125 inches × 0.03 inches, but not limited to specific sizes). Pockets that allow the insertion of functional features such as magnetic stripes, contact or dual interface chip modules, booster antennas for dual interface cards, holograms, signature panels, or branding can be created by the injection molding process. The ceramic card body can also be made from a larger ceramic block and machined to the desired size. Also, the ceramic parts may be 3D printed for manufacturing. In a preferred embodiment, the ceramic can include sintered zirconium dioxide, but is not particularly limited and may include one or more oxides such as alumina, beryllium, ceria, ceramic, carbide, boride, nitride, or silicate.

[0078] The solid ceramic card provides functional advantages over existing premium metal cards in that it does not particularly require machining, does not generate electrostatic discharge, and does not interfere with RF radiation for contactless transactions. Aesthetically, the solid ceramic card can be obtained in various colors by adding pigments to the ceramic compound and further modified by laser marking and adding desired features such as laser signatures or decorative design features. Security elements such as through-holes, windows, or microtext can also be added by laser, mechanical or chemical etching, or any method known in the art.

[0079] As shown in FIGS. 11B, 11C, 11D, and 11E, it is also possible to provide a transaction card including a metal-ceramic composite material containing metal and ceramic. In certain embodiments, the ceramic insert can be placed in a metal and metal-plastic card to create unique features while maintaining most of the weight of the metal card, and can improve the available colors, textures, and laser characteristics. For example, such an insert can be adhered by mechanically creating a pocket in the core, placing an adhesive in the pocket, and adhering the ceramic insert within the pocket. In another embodiment, the ceramic insert and the created pocket can be configured such that the ceramic insert is held in place by press fitting. In yet another embodiment, the core can have one or more tapped holes disposed at its edge such that the core functions as a frame and a set screw disposed in the tapped hole holds the ceramic insert within the frame. However, the adhesion of the ceramic insert to the core is not limited to a particular method.

[0080] A metal core card with ceramic coatings on both sides and one side may be provided (see FIGS. 11B, 11C, 11D, and 11E). The metal core is not particularly limited, but may include brass, steel, nickel, palladium, silver, gold, platinum, aluminum, or other suitable metals or metal alloys known in the art, and may include a solid metal having a thickness of 0.024 inches to 0.030 inches (but not limited to a specific thickness). The metal core may also be a composite structure such as a core containing a first metal having a thickness of 0.001 inches to 0.029 inches (but not limited to a specific thickness) bonded to a second metal having a thickness of 0.001 inches to 0.029 inches (but not limited to a specific thickness), or may include any plurality of layers constituting a card of a desired thickness. This composite material may be desirable for a particular weight or color that appears when the ceramic is laser marked. Utilizing a composite metal can also increase cost efficiency. Metal-plastic composite cards having ceramic coatings on one side and both sides can achieve the desired manufacturing cost, weight, and aesthetic effects.

[0081] In one exemplary embodiment, a metal core (e.g., steel) with a thickness of 0.02 inches can be bonded to a PVC layer with a thickness of 0.007 inches on one side having a ceramic coating on the unbonded surface of the metal core. The ceramic can be applied as a spray coating, which is then cured by heat, air, or UV. After curing, the coating is typically 0.001 inches to 0.003” thick, depending on the desired appearance of the coating. These coatings can be manufactured in a variety of colors. Typically, the coating consists of zirconium dioxide, ceramic microparticles containing aluminum silicate, and a curable resin binder suspended in a volatile organic carrier solution, such as CERAKOTE® ceramic coating manufactured by NIC Industries, Inc. Once sprayed and cured, the coating provides the card with a unique color and texture, typically in a very durable finish that reaches thousands of Taber abrasion cycles. The ceramic coating can be modified using mechanical or chemical etching, inkjet printing, laser marking, and other methods known in the art to provide desired aesthetic effects, such as the design on the card shown in FIG. 11E. The magnetic stripe, signature panel, branding, hologram, and other functional features of the transaction card can be applied directly to the ceramic surface (see 123, 125 in FIG. 11C), or pockets can be created by mechanical or laser etching, etc. (see FIG. 10C) to bond such features to the metal core.

[0082] Accordingly, an exemplary method for manufacturing an exemplary ceramic card using a metal core can include the following steps: 1. Prepare a metal core sheet (optional - the step of preparing a metal core can include laminating a metal foil, such as aluminum foil, to one or more surfaces of an inner sub-core, where the sub-core can include any material, but typically can include metal or plastic).

[0083] 2. Add fixing means such as fixing holes and fixtures used to hold the sheet in place while the following processes are being performed to the metal core.

[0084] 3. Create a surface shape such as a pocket for holding a booster antenna used in connection with an RFID chip that can be placed under the ceramic layer. Also, a pocket is provided in the core, which ultimately becomes a recess in the ceramic coating, where components (e.g., RFID chips) are later adhered at the end of processing to provide a smooth surface in the final product.

[0085] 4. Apply a surface finish to the core (bead blasting, tumbling, brushing, etc.).

[0086] 5. Coat one or both sides with ceramic.

[0087] 6. Laser mark the ceramic-coated metal sheet with a design or other surface shape and perform other mechanical, chemical, or laser modifications necessary to facilitate the later adhesion of other components. For example, the edges of any pockets or recesses can be treated to better conform to the shape added in the next step or area where the adhesive is applied, or can be roughened for better adhesion.

[0088] 7. Use a CNC (Computer Numerical Control) machine or the like to cut the sheet into card blanks.

[0089] 8. Apply functional and security features (magnetic stripe, chip, hologram, etc.) to the individual card blanks. As described above, such features may be placed in pockets created early in the processing or adhered with an adhesive to a roughened area. However, since the magnetic stripe is preferably applied to a surface that is as planar and flat as possible, it is preferably applied directly onto the ceramic coating.

[0090] In the market of identity cards traditionally composed of composite plastics or polycarbonates, ceramics offer new possibilities to extend the lifespan of the cards and make forgery more difficult. Colored and clear ceramic coatings can be applied to a plastic core to create a more durable material when tested by ISO standard flexibility and abrasion tests. Furthermore, these materials are much more difficult to forge, enabling unique laser marking characteristics and allowing the inclusion of unique phosphors in the ceramics to shift incident light up and down, creating a unique thin "watermark" as part of the ID. Some embodiments of the present invention are described in the following items [1]-

[57] . [1] A method of creating a card having a predetermined appearance, comprising: selecting a thin decorative layer and processing the thin decorative layer to have a thickness in the range of 0.0005 inches to 0.014 inches, wherein the thin decorative layer is one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material; the above step; and selecting a thick core layer to form the body of the card, the thick core layer having a thickness in the range of 0.005 inches to 0.032 inches and first and second surfaces that are substantially parallel to each other, the thick core layer being (a) a thick metal core layer, or (b) a ceramic-coated metal, or (c) a ceramic-coated polymer, or (d) a solid ceramic material; the above step; and adhering the thin decorative layer to the first surface of the thick core layer; the above method comprising the steps of [2] The step of adhering the thin layer and the thick layer includes laminating the layers, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The method according to item 1, further comprising the step of applying a laser light source to the anodized aluminum layer to modify the color, appearance, and texture of the card. [3] The step of adhering the thin layer and the thick layer includes laminating the layers, The thin decorative layer is an anodized aluminum layer having a predetermined color, The method according to item 1, further comprising the step of forming a hard coat layer on the anodized aluminum layer. The method according to item 1, further comprising the step of applying a laser light source to the hard coat layer and the anodized aluminum layer to modify at least one of the color and feel of the card. [4] The method according to item 3, wherein the hard coat layer is designed to have a color different from the color of the anodized aluminum. [5] The method according to item 2, further comprising a polymer layer adhered to a second surface of the thick core layer. [6] A polymer layer adhered to a second surface of the thick core layer, and an integrated circuit module disposed within the card to enable at least one of (a) radio frequency (RF) transmission between the card and an external card reader and (b) contact reading between the card and a contact reader. The method according to item 2. [7] The method according to item 2, further comprising an embossable polymer layer adhered to the anodized aluminum layer. The method according to item 2, further comprising the step of embossing the polymer layer and the anodized aluminum layer. [8] The thick core layer is a thick metal layer, the thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The thick metal layer is designed to have a different color, The method further comprising at least one additional layer having a preselected color. The method according to item 1, further comprising the step of applying a laser light source to the anodized aluminum layer, the thick metal layer, and the additional layer to modify at least one of the color and the feel of the card. [9] The decorative board layer of the plant-derived material is a layer of natural wood with a low lignin content, The processing of the wood decorative board layer includes (a) the step of sanding the back surface of the wood layer until the wood layer has a thickness in the range of 0.001 inches to 0.015 inches, and (b) the step of applying an oil film to the wood layer to maintain its appearance when the wood layers are laminated. The method according to item 1.

[10] The method according to item 9, further comprising the step of chamfering the outer edge of the wood layer to prevent the wood layer from being worn out or peeled off.

[11] The decorative board layer of the animal-derived material is a layer of natural leather having a top surface and a bottom surface, The processing of the leather decorative board layer includes treating the bottom surface of the leather layer such that the thickness of the leather layer is in the range of 0.001 inches to 0.015 inches and its bottom surface is adapted to receive an adhesive. The method according to item 1.

[12] The step of embossing the top surface of the leather layer, The method according to item 11, including the step of forming a first assembly consisting of the leather layer having a bottom surface adhered to the first surface of the thick core layer.

[13] The thick core layer is a thick metal layer, the embossed leather layer is the first leather layer, The step of forming a second assembly, including positioning a second leather layer having a top surface and a bottom surface, wherein the top surface of the second leather layer faces the top surface of the first embossed leather layer of the first assembly. The method according to item 12, further comprising the steps of laminating the first and second leather layers and the thick metal layer, such that the embossing pattern of the first leather layer is transferred to the second leather layer and the components of the first assembly are laminated.

[14] The decorative board layer of the aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material, The method according to item 1, further comprising the step of applying a laser light source to the cement or epoxy layer mixed with carbon particles to vaporize the carbon particles to generate a high-contrast pattern.

[15] The method according to item 1, wherein the step of adhering the thin decorative layer to the thick core layer includes forming a pocket in the surface of the thick core layer and firmly adhering one of the thin decorative layers in the pocket.

[16] The method according to item 15, wherein the depth of the pocket is made substantially equal to the thickness of the decorative layer.

[17] The thin decorative layer is an anodized metal layer, The method according to item 1, further comprising the step of dyeing a plurality of colors of the anodized metal layer.

[18] The thin decorative layer is an anodized metal layer, The method according to item 1, further comprising the step of modifying the anodized layer by one of printing graphics such as screen printing, sublimation printing, any digital printing system, laser engraving, mechanical engraving, die cutting, or embossing.

[19] The thin decorative layer is an anodized metal layer, The method according to item 1, wherein the anodized metal layer is selectively extended along the surface of the card as (a) the full length and width of the card, (b) as a patch, (c) as a stripe, or (d) as a decorative design.

[20] The method according to item 1, further comprising the step of adhering the thin decorative layer to the second surface of the thick metal layer.

[21] The thin decorative layer adhered to the second surface of the thick metal layer includes one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material, according to the method of item 20.

[22] The thick core layer is a thick metal layer, The thin decorative layer is a layer of a ceramic material, The step of selecting and processing the thin decorative layer includes the step of applying the ceramic layer to the thick metal layer and bonding it to the thick metal layer, according to the method of item 1.

[23] The thin decorative layer is a thin anodized metal layer having a predetermined colored region extending to a predetermined depth within the thin metal layer, (a) The step of removing a selected portion of the colored region to the predetermined depth according to a design pattern, and (b) electroplating the thin anodized metal layer with an electroplated metal having a color other than the predetermined colored region to generate a pattern displaying the color of the electroplated metal and the predetermined colored region, according to the method of item 1.

[24] The thin anodized metal layer is a thin layer of aluminum having a region of an upper sublayer dyed to have the predetermined color, The step of removing a selected portion of the colored region includes the step of exposing a selected portion of the anodized aluminum layer using a laser device, The electroplated metal is a precious metal such as gold, according to the method of item 23.

[25] A card having a front side and a back side, A thick core layer having a thickness in the range of 0.005 inches to 0.032 inches, the thick core layer forming the bulk of the card and having a predetermined color, the thick core layer having first and second surfaces extending substantially parallel to each other, the thick core layer, A thin decorative layer adhered to the first surface of the thick core layer for providing at least one of color and texture to the card, having a thickness in the range of 0.0005 inches to 0.03 inches, and being one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline fabric material, the card comprising the thin decorative layer.

[26] The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color and having a pattern formed within the anodized layer for displaying the color of the anodized aluminum and the thick metal layer thereunder. The card according to item 25, having a unique texture corresponding to the formed pattern.

[27] The thick core layer is a thick metal layer, The thin decorative layer is an anodized metal layer having a predetermined color. A hard coat layer is formed on the anodized aluminum layer. A pattern is formed within the hard coat layer. The card according to item 25, wherein the anodized aluminum layer generates a pattern showing the colors of the hard coat layer, the anodized layer, and the thick metal layer.

[28] The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer having a predetermined color. A colored hard coat layer is formed on the anodized aluminum layer. An additional layer is adhered to the thick metal having a color different from the other layers of the card. Patterns are formed within the hard coat layer and the anodized aluminum layer. The card according to item 25, wherein the thick metal layer generates a pattern that displays the colors of the hard coat layer, the anodized layer, the thick metal layer, and the additional layer.

[29] The thick core layer is a thick metal layer, The card according to item 25, further comprising a polymer layer adhered to a second surface of the thick core layer.

[30] The thick core layer is a thick metal layer, (a) a polymer layer adhered to the thick metal layer; and (b) an integrated circuit module located within the card to enable at least one of (i) wireless radio frequency (RF) transmission between the card and an external card reader and (ii) contact reading between the card and a contact reader. The card according to item 25.

[31] The thick core layer is a thick metal layer, The card according to item 25, further comprising an embossable polymer layer adhered to the anodized aluminum layer, The card according to item 25, wherein a pattern is embossed in the polymer layer to generate a corresponding pattern that can be felt.

[32] The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The thick metal layer is designed to have different colors, The card according to item 25, further comprising at least one additional layer having a preselected color, Selected portions of these layers are removed by one of laser irradiation, machining, or chemical etching, such that their appearance correlates with the colors of these layers and the texture of the card correlates with a formed pattern. The card according to item 25.

[33] The veneer layer of the plant-derived material is a layer of actual wood with a low lignin content, The wood layer has a thickness in the range of 0.001 inches to 0.010 inches, The card according to item 25, wherein the actual wood layer has an upper surface protected by an oil film disposed along the upper surface.

[34] The card according to item 33, wherein an outer edge portion of the wood layer is chamfered to prevent abrasion or peeling of the wood layer.

[35] The thick core layer is a thick metal layer, The decorative veneer layer of the animal-derived material is an actual leather layer having an upper surface and a bottom surface, and the upper surface thereof has a unique pattern related to actual leather. The leather decorative veneer layer has a thickness in the range of 0.001 inch to 0.020 inch. The bottom surface of the leather layer is modified and treated to receive an adhesive. The card according to item 25, wherein the upper surface of the leather layer is embossed and the bottom surface thereof is adhered to the thick metal layer via an adhesive layer.

[36] The decorative veneer layer of the aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material. The card according to item 25, wherein a pattern is formed on the decorative veneer layer by vaporization of carbon particles.

[37] The card according to item 25, wherein the anodized metal layer is a multicolor metal layer.

[38] The thick core layer is a thick metal layer, and the thin decorative layer adhered to the first surface of the thick metal layer is a first thin decorative layer. The card according to item 25, wherein a second thin decorative layer is adhered to the second surface of the thick metal layer.

[39] The second thin decorative layer is one of (a) an anodized metal layer, (b) a decorative veneer layer of a plant-derived material such as wood, (c) a decorative veneer layer of an animal-derived material such as leather, (d) a decorative veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystal cloth material, according to item 38.

[40] The card according to item 38, wherein the thin decorative layer adhered to the first surface of the thick metal layer is different from the thin decorative layer adhered to the second surface of the thick metal layer.

[41] The thick core layer is a thick metal layer, A pocket is formed on the first surface of the thick metal layer, The card according to item 25, wherein a thin decorative layer is adhered to the thick metal layer within the pocket.

[42] The card according to item 41, wherein the thin decorative layer adhered to the thick metal layer within the pocket is a layer of a crystalline fabric material.

[43] The second thin decorative layer is an anodized metal foil, The card according to item 38, further comprising a signal panel and a magnetic stripe adhered to the second thin decorative layer.

[44] The second thin decorative layer is an anodized metal foil, The card according to item 38, further comprising a polymer layer adhered to the second thin decorative layer, and a signal panel and a magnetic stripe adhered to the polymer layer.

[45] The card according to item 25, wherein the thin decorative layer is a thin anodized metal layer having a predetermined colored region extending to a predetermined depth within the thin anodized metal layer, a selected portion of the colored region is removed to the predetermined depth according to a design pattern, a specific metal having a color other than the predetermined colored region is electroplated within the removed selected region to generate a pattern displaying the color of the specific metal and the predetermined colored region.

[46] The card according to item 45, wherein the thin anodized metal layer is a thin layer of aluminum having an upper sub-layer region dyed to have the predetermined color, and the specific metal is a noble metal such as gold.

[47] The thick core layer is a thick metal layer, a ceramic layer is adhered to a first surface of the thick metal layer, and a thin decorative layer other than the ceramic layer is adhered to the ceramic layer. The card according to item 25.

[48] The thick core layer is a thick metal layer, a first ceramic layer is adhered to a first surface of the thick metal layer, and a second ceramic layer is adhered to a second surface of the thick metal layer. The card according to item 25.

[49] The thick core layer is a thick ceramic layer. The card according to item 25.

[50] A metal card, A thick metal layer having a thickness in the range of 0.005 inches to 0.035 inches, the thick metal layer forming the bulk of the card and having a predetermined color, the thick metal layer having a top surface and a bottom surface, and the thick metal layer, A pocket formed in the top surface of the thick metal layer, the depth of the pocket being in the range of 0.003 inches to 0.030 inches downward from the surface of the thick metal layer and the boundary around the outer peripheral portion of the metal layer, the pocket, A thin decorative layer adhered to the pocket formed in the top surface of the thick metal layer. The card as described above.

[51] The thin decorative layer has a thickness in the range of 0.005 inches to 0.030 inches, The thin decorative layer is one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystal cloth material. The metal card according to item 50.

[52] The anodized metal layer is one of aluminum, titanium, zinc, niobium, tantalum, or any other metal that can be anodized. The card according to item 51.

[53] The card according to item 51, wherein the decorative board layer is one of wood, leather, ceramic, crystal cloth material, cement, or epoxy.

[54] A method of making a card, selecting a thick metal layer having substantially parallel top and bottom surfaces, the thick metal layer having a thickness in the range of 0.005 inches to 0.033 inches, the above step, and forming a pocket on the top surface of the thick metal layer, the depth of the pocket extending downward from the surface of the thick metal layer and the boundary around the outer peripheral portion of the metal layer by 0.003 inches to 0.030 inches, the above step, and adhering a thin decorative layer to the pocket formed within the top surface of the thick metal layer to provide at least one of color and texture to the card, the above method comprising.

[55] The thin decorative layer has a thickness in the range of 0.003 inches to 0.030 inches, The thin decorative layer includes one of (a) an anodized metal layer, (b) a decorative board layer of a plant-derived material such as wood, (c) a decorative board layer of an animal-derived material such as leather, and (d) a decorative board layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material. The metal card according to item 54.

[56] A method of making a card, selecting a layer of a first leather-like material having a top and a bottom surface, and embossing a pattern on the top surface of the first leather-like material, and selecting a layer of a second leather-like material having a top and a bottom surface, and forming an assembly by disposing the top surface of the second leather-like layer on the top surface of the embossed first layer and laminating and adhering the first layer onto a metal substrate, and laminating the assembly so that the embossed first layer is laminated with the metal layer to form a card or a card sub-assembly, and simultaneously embossing the top surface of the second leather-like layer, the above method comprising.

[57] A card having a front side and a back side, A thick ceramic layer having a thickness in the range of 0.005 inches to 0.032 inches, wherein the thick ceramic layer forms the bulk of the card, has a predetermined color, and the thick metal layer has first and second surfaces that extend substantially parallel to each other, the thick ceramic layer, A thin decorative layer adhered to a first surface of the thick ceramic layer for providing at least one of color and texture to the card, wherein the thin decorative layer has a thickness in the range of 0.0005 inches to 0.014 inches, and the thin decorative layer is (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystal cloth material, one of the above thin decorative layers, and the above card having the same.

Claims

1. A method of creating a card having a predetermined appearance, comprising: selecting a thin decorative layer and processing the thin decorative layer to have a thickness in the range of 0.0005 inches to 0.014 inches, where the thin decorative layer is one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material; the above step; selecting a thick core layer to form the body of the card, the thick core layer having a thickness in the range of 0.005 inches to 0.032 inches and first and second surfaces that are substantially parallel to each other, the thick core layer being (a) a thick metal core layer, or (b) a ceramic-coated metal, or (c) a ceramic-coated polymer, or (d) a solid ceramic material; the above step; and adhering the thin decorative layer to the first surface of the thick core layer; The above method comprising the above steps.

2. The step of adhering the thin layer and the thick layer includes laminating the layers, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The method according to claim 1, further comprising applying a laser light source to the anodized aluminum layer to modify the color, appearance, and texture of the card.

3. The step of adhering the thin layer and the thick layer includes laminating the layers, The thin decorative layer is an anodized aluminum layer having a predetermined color, The method further comprising forming a hard coat layer on the anodized aluminum layer, The method according to claim 1, further comprising applying a laser light source to the hard coat layer and the anodized aluminum layer to modify at least one of the color and feel of the card.

4. The method according to claim 3, wherein the hard coat layer is designed to have a color different from the color of the anodized aluminum.

5. The method according to claim 2, further comprising a polymer layer adhered to the second surface of the thick core layer.

6. A polymer layer adhered to the second surface of the thick core layer, and The method according to claim 2, further comprising an integrated circuit module disposed within the card to enable at least one of (a) radio frequency (RF) transmission between the card and an external card reader and (b) contact reading between the card and a contact reader.

7. Further comprising an embossable polymer layer adhered to the anodized aluminum layer, The method according to claim 2, further comprising the step of embossing the polymer layer and the anodized aluminum layer.

8. The thick core layer is a thick metal layer, the thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The thick metal layer is designed to have a different color, Further comprising at least one additional layer having a preselected color, The method according to claim 1, further comprising the step of applying a laser light source to the anodized aluminum layer, the thick metal layer, and the additional layer to modify at least one of the color and the feel of the card.

9. The veneer layer of the plant-derived material is a layer of natural wood with a low lignin content, The processing of the wood veneer layer includes (a) the step of sanding the back surface of the wood layer until the wood layer has a thickness in the range of 0.001 inches to 0.015 inches, and (b) the step of applying an oil film to the wood layer to maintain its appearance when the wood layers are laminated. The method according to claim 1.

10. The method according to claim 9, further comprising the step of chamfering the outer edge of the wood layer to prevent abrasion or peeling of the wood layer.

11. The veneer layer of the animal-derived material is a layer of natural leather having a top surface and a bottom surface, The processing of the leather veneer layer includes treating the bottom surface of the leather layer such that the thickness of the leather layer is in the range of 0.001 inches to 0.015 inches and its bottom surface is adapted to receive an adhesive. The method according to claim 1.

12. The step of embossing the top surface of the leather layer, The method according to claim 11, comprising the step of forming a first assembly consisting of the leather layer having a bottom surface adhered to the first surface of the thick core layer.

13. The thick core layer is a thick metal layer, the embossed leather layer is a first leather layer, Forming a second assembly including positioning a second leather layer having a top and a bottom surface such that the top surface of the second leather layer faces the top surface of the first embossed leather layer of the first assembly; The method of claim 12, further comprising laminating the first and second leather layers and the thick metal layer, whereby the embossed pattern of the first leather layer is transferred to the second leather layer and the components of the first assembly are laminated.

14. The veneer layer of the aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material, The method of claim 1, further comprising applying a laser light source to the cement or epoxy layer mixed with carbon particles to vaporize the carbon particles to produce a high-contrast pattern.

15. The method of claim 1, wherein the step of adhering the thin decorative layer to the thick core layer includes forming a pocket within the surface of the thick core layer and firmly adhering one of the thin decorative layers within the pocket.

16. The method of claim 15, wherein the depth of the pocket is made substantially equal to the thickness of the decorative layer.

17. The thin decorative layer is an anodized metal layer, The method of claim 1, further comprising the step of dyeing a plurality of colors of the anodized metal layer.

18. The thin decorative layer is an anodized metal layer, The method of claim 1, further comprising the step of modifying the anodized layer by one of printing graphics such as screen printing, sublimation printing, any digital printing system, laser engraving, mechanical engraving, die cutting, or embossing.

19. The thin decorative layer is an anodized metal layer, The method of claim 1, wherein the anodized metal layer is selectively extended along the surface of the card (a) over the entire length and width of the card, (b) as a patch, (c) as a stripe, or (d) as a decorative design.

20. The method of claim 1, further comprising the step of adhering a thin decorative layer to a second surface of the thick metal layer.

21. The thin decorative layer adhered to the second surface of the thick metal layer includes one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material, according to the method of claim 20.

22. The thick core layer is a thick metal layer, The thin decorative layer is a layer of a ceramic material, The step of selecting and processing the thin decorative layer includes the step of applying the ceramic layer to the thick metal layer and bonding it to the thick metal layer, according to the method of claim 1.

23. The thin decorative layer is a thin anodized metal layer having a predetermined colored region extending to a predetermined depth within the thin metal layer, The method of claim 1 further includes (a) removing a selected portion of the colored region to the predetermined depth according to a design pattern, and (b) electroplating the thin anodized metal layer with an electroplated metal having a color other than the predetermined colored region to generate a pattern displaying the color of the electroplated metal and the predetermined colored region.

24. The thin anodized metal layer is a thin layer of aluminum having a region of an upper sublayer dyed to have the predetermined color, The step of removing a selected portion of the colored region includes the step of exposing a selected portion of the anodized aluminum layer using a laser device, The electroplated metal is a noble metal such as gold, according to the method of claim 23.

25. A card having a front side and a back side, A thick core layer having a thickness in the range of 0.005 inches to 0.032 inches, the thick core layer forming the bulk of the card and having a predetermined color, the thick core layer having first and second surfaces extending substantially parallel to each other, the thick core layer; A thin decorative layer adhered to the first surface of the thick core layer for providing at least one of color and texture to the card, having a thickness in the range of 0.0005 inches to 0.03 inches, and being one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material, the card including the thin decorative layer.

26. The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color and having a pattern formed in the anodized layer to display the color of the anodized aluminum and the thick metal layer thereunder, The card according to claim 25, wherein the card has a unique texture corresponding to the formed pattern.

27. The thick core layer is a thick metal layer, The thin decorative layer is an anodized metal layer having a predetermined color, A hard coat layer is formed on the anodized aluminum layer, A pattern is formed in the hard coat layer, The card according to claim 25, wherein the anodized aluminum layer generates a pattern showing the colors of the hard coat layer, the anodized layer, and the thick metal layer.

28. The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer having a predetermined color, A colored hard coat layer is formed on the anodized aluminum layer, An additional layer is adhered to the thick metal having a color different from the other layers of the card, Patterns are formed in the hard coat layer and the anodized aluminum layer, The card according to claim 25, wherein the thick metal layer generates a pattern showing the colors of the hard coat layer, the anodized layer, the thick metal layer, and the additional layer.

29. The thick core layer is a thick metal layer, The card according to claim 25, further including a polymer layer adhered to the second surface of the thick core layer.

30. The thick core layer is a thick metal layer, (a) a polymer layer adhered to the thick metal layer; and (b) (i) an integrated circuit module located within the card to enable at least one of (i) wireless radio frequency (RF) transmission between the card and an external card reader and (ii) contact reading between the card and a contact reader. The card according to claim 25, further comprising.

31. The thick core layer is a thick metal layer, Further comprising an embossable polymer layer adhered to the anodized aluminum layer, The card according to claim 25, wherein a pattern is embossed in the polymer layer to generate a corresponding pattern that can be felt.

32. The thick core layer is a thick metal layer, The thin decorative layer is an anodized aluminum layer designed to have a predetermined color, The thick metal layer is designed to have a different color, Further comprising at least one additional layer having a preselected color, Selected portions of these layers are removed by one of laser irradiation, machining, or chemical etching, such that its appearance correlates with the color of these layers and the texture of the card correlates with a formed pattern. The card according to claim 25.

33. The veneer layer of the plant-derived material is a layer of actual wood with a low lignin content, The wood layer has a thickness in the range of 0.001 inches to 0.010 inches, The card according to claim 25, wherein the layer of actual wood has an upper surface protected by an oil film disposed along the upper surface.

34. The card according to claim 33, wherein the outer edge of the wood layer is chamfered to prevent chipping or peeling of the wood layer.

35. The thick core layer is a thick metal layer, The veneer layer of the animal-derived material is an actual leather layer having an upper surface and a bottom surface, the upper surface of which has a unique pattern associated with actual leather, The leather veneer layer has a thickness in the range of 0.001 inches to 0.020 inches, The bottom surface of the leather layer is modified and treated to accept an adhesive, The card according to claim 25, wherein the upper surface of the leather layer is embossed and its bottom surface is adhered to the thick metal layer via an adhesive layer.

36. The veneer layer of the aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material, The card according to claim 25, wherein a pattern is formed in the veneer layer by vaporization of carbon particles.

37. The card according to claim 25, wherein the anodized metal layer is a multi-color metal layer.

38. The thick core layer is a thick metal layer, the thin decorative layer adhered to the first surface of the thick metal layer is a first thin decorative layer, The card according to claim 25, wherein a second thin decorative layer is adhered to the second surface of the thick metal layer.

39. The second thin decorative layer is one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline fabric material. The card according to claim 38.

40. The card according to claim 38, wherein the thin decorative layer adhered to the first surface of the thick metal layer is different from the thin decorative layer adhered to the second surface of the thick metal layer.

41. The thick core layer is a thick metal layer, A pocket is formed on the first surface of the thick metal layer, The card according to claim 25, wherein a thin decorative layer is adhered to the thick metal layer within the pocket.

42. The card according to claim 41, wherein the thin decorative layer adhered to the thick metal layer within the pocket is a layer of a crystalline fabric material.

43. The second thin decorative layer is an anodized metal foil, The card according to claim 38, further comprising a signal panel and a magnetic stripe adhered to the second thin decorative layer.

44. The second thin decorative layer is an anodized metal foil, The card according to claim 38, further comprising a polymer layer adhered to the second thin decorative layer, a signal panel adhered to the polymer layer, and a magnetic stripe.

45. The card according to claim 25, The thin decorative layer is a thin anodized metal layer having a predetermined colored region extending to a predetermined depth within the thin anodized metal layer, A selected portion of the colored region is removed to the predetermined depth according to a design pattern, A specific metal having a color other than the predetermined colored region is electroplated within the removed selected region to generate a pattern displaying the color of the specific metal and the predetermined colored region. The above card.

46. The thin anodized metal layer is a thin layer of aluminum having an upper sub-layer region dyed to have the predetermined color, and the specific metal is a noble metal such as gold. The card according to claim 45.

47. The thick core layer is a thick metal layer, a ceramic layer is adhered to a first surface of the thick metal layer, and a thin decorative layer other than the ceramic layer is adhered to the ceramic layer. The card according to claim 25.

48. The thick core layer is a thick metal layer, a first ceramic layer is adhered to a first surface of the thick metal layer, and a second ceramic layer is adhered to a second surface of the thick metal layer. The card according to claim 25.

49. The thick core layer is a thick ceramic layer. The card according to claim 25.

50. A metal card, A thick metal layer having a thickness in the range of 0.005 inches to 0.035 inches, the thick metal layer forming the bulk of the card and having a predetermined color, the thick metal layer having a top surface and a bottom surface, and the thick metal layer, A pocket formed in the top surface of the thick metal layer, the depth of the pocket being in the range of 0.003 inches to 0.030 inches downward from the surface of the thick metal layer and the boundary around the outer peripheral portion of the metal layer. The pocket, A thin decorative layer adhered to the pocket formed in the top surface of the thick metal layer. The card as described above.

51. The thin decorative layer has a thickness in the range of 0.005 inches to 0.030 inches, The thin decorative layer is one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystal cloth material. The metal card according to claim 50.

52. The anodized metal layer is one of aluminum, titanium, zinc, niobium, tantalum, or any other metal that can be anodized. The card according to claim 51.

53. The veneer layer is one of wood, leather, ceramic, crystal cloth material, cement, or epoxy. The card according to claim 51.

54. A method of making a card, Selecting a thick metal layer having substantially parallel top and bottom surfaces, wherein the thick metal layer has a thickness in the range of 0.005 inches to 0.033 inches, the above step, Forming a pocket on the top surface of the thick metal layer, wherein the depth of the pocket extends downward 0.003 inches to 0.030 inches from the surface of the thick metal layer and the boundary around the outer peripheral portion of the metal layer, the above step, Adhering a thin decorative layer to the pocket formed within the top surface of the thick metal layer to provide at least one of color and texture to the card, the above method comprising.

55. The thin decorative layer has a thickness in the range of 0.003 inches to 0.030 inches, The thin decorative layer includes one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, and (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, the metal card according to claim 54.

56. A method of creating a card, comprising: Selecting a layer of a first leather-like material having a top surface and a bottom surface; Embossing a pattern on the top surface of the first leather-like material; Selecting a layer of a second leather-like material having a top surface and a bottom surface; Forming an assembly comprising placing the top surface of the second leather-like layer on the top surface of the embossed first layer and laminating and adhering the first layer on a metal substrate; Laminating the assembly so that the embossed first layer is laminated with the metal layer to form a card or a card sub-assembly, and simultaneously embossing the top surface of the second leather-like layer, the above method comprising.

57. A card having a front side and a back side, comprising: A thick ceramic layer having a thickness in the range of 0.005 inches to 0.032 inches, the thick ceramic layer forming the bulk of the card and having a predetermined color, the thick metal layer having first and second surfaces extending substantially parallel to each other, the thick ceramic layer, A thin decorative layer adhered to the first surface of the thick ceramic layer for providing at least one of color and texture to the card, the thin decorative layer having a thickness in the range of 0.0005 inches to 0.014 inches, and the thin decorative layer being one of (a) an anodized metal layer, (b) a veneer layer of a plant-derived material such as wood, (c) a veneer layer of an animal-derived material such as leather, (d) a veneer layer of an aggregate binder material such as cement or epoxy mixed with a laser-reactive material, (e) a ceramic layer, and (f) a layer of a crystalline cloth material, the card having the thin decorative layer as described above.

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