Trade and ID cards with selected textures and colors

Abstract

Metal and / or ceramic cards are provided in a wide range of colors and textures. [Solution] Cards made in accordance with the present invention include a specially treated thin decorative layer bonded to a thick core layer of metal or ceramic material, where the thin decorative layer is designed to provide a selected color and / or a selected texture to the surface of the metal card. Decorative layers used to practice the present invention include (a) an anodized metal layer, or (b) a layer of material derived from plant or animal matter (e.g., wood, leather); or (c) a combination of an aggregate binder material (e.g., cement, mortar, epoxy) mixed with a laser-reactive material (e.g., micronized carbon), or (d) a ceramic layer, and (f) a layer of crystalline cloth material. The card may be a dual-interface smart card that can be read contactlessly and / or contact-wise.

Description

[Technical field]

[0001] This application claims priority to provisional application Ser. No. 62 / 001706, filed May 22, 2014, entitled "Transaction and ID Cards with Controlled Color," the teachings of which are incorporated herein by reference. This application also claims priority to provisional application Ser. No. 62 / 074305, filed November 3, 2014, entitled "Ceramic Transaction and ID Cards with Controlled Color," the teachings of which are incorporated herein by reference.

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

[0003] It has become desirable for the affluent market to offer metal or ceramic cards to give the card owner a sense of affluence and prestige, and it is also desirable to offer different colors and textures on metal cards to provide a nice look and feel, and / or a degree of personalization.

[0004] It is known to use physical vapor deposition (PVD) to color metal transaction cards, but PVD is limited in its color range and is relatively expensive. PVD is also highly dependent on the substrate on which it is deposited. PVD is a vacuum process that involves high heat and batch operations, and the process requires individual racking and turning of parts for color uniformity, which is expensive. It subjects the metal to high temperatures that can cause it to shrink and distort.

[0005] Some metal cards use printed PVC layers or other polymers to decorate the exterior of the card. The use of these polymer layers has undesirable properties such as minimum print thickness, weight loss of the metal card due to the thickness of the polymer, and challenges in laminating dissimilar materials. The use of different thicknesses and compounds can also cause the part to warp or bow due to uneven shrinkage during platen lamination. Summary of the Invention [Problem to be solved by the invention]

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

[0007] The cards produced according to the invention include a specially treated thin decorative layer adhered to one or both sides of a thick core layer of metal, ceramic-coated metal or polymer, or solid ceramic material, where the thin decorative layer is designed to provide a selected color and / or a selected texture to the surface of the card. The decorative layers used in the practice of the invention include (a) an anodized metal layer; or (b) a layer of material derived from plant or animal matter (e.g., wood, leather); or (c) a combination of a binder material (e.g., cement, mortar, epoxide) 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 contactless and / or contact.

[0008] The manufacture of metal cards according to the present invention generally involves the preparation and processing of a thin decorative layer and adhering 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 primarily on the front side of the metal card, but can also be provided on the back side of the card.

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

[0010] In the case of aluminum films, for example, the anodized oxide structure originates from the aluminum substrate and is composed entirely of aluminum oxide. This aluminum oxide is not applied to the surface like a paint or plating, but is completely integrated with the underlying aluminum substrate and will not crumble or flake off. It has a highly ordered porous structure that allows for secondary processes such as coloring and sealing.

[0011] Anodizing can be done by immersing the aluminum in an acid electrolyte bath (tank) and passing an electric current through the medium. A cathode is attached inside the anodizing tank. The aluminum acts as the anode, and thus oxygen ions are released from the electrolyte and combine with the aluminum atoms on the surface of the part being anodized. Anodizing is therefore a highly controlled oxidation affair, an enhancement of a naturally occurring phenomenon. Color can be introduced by passing the anodized foil through a dye bath of the appropriate (desired) color, followed by a sealer bath.

[0012] The use of a colored anode layer on a metal layer provides greater flexibility and cost savings. Using printed anode materials to replace polymeric materials overcomes these challenges because metals are denser than polymers and do not have minimum print thickness limitations. The compositions and methods can be used on all types of transaction and ID cards, including contactless, contact, and dual interface smart cards.

[0013] In the present invention, the color and / or texture of the anodized layer can be further modified (a) by dyeing the anodized layer in one or more colors, or (b) by 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, machine engraving, die cutting, or embossing. The anodized metal layer can be used on the card as a full-surface material (i.e., extending the entire length and width of the card), patches, stripes, or other decorative designs. The anodized metal can be laser marked or otherwise engraved or marked, and base or precious metals can be electroplated onto the anodized surface in selective patterns or flood coatings.

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

[0015] If the decorative layer is a layer of material derived from plant matter (e.g. wood), special care must be taken to treat the decorative layer before and during its adhesion to the metal substrate in order to maintain its original (unique) pattern and texture. Texture as used herein refers to the visual and especially tactile qualities of a surface. It includes the feel, texture, appearance, and graininess of the surface.

[0016] Similarly, when the decorative layer is a layer of material derived from animal substances (e.g. leather), special processes have had to be developed to treat the decorative layer in such a way that it maintains its original (unique) pattern and texture before and during adhesion of the decorative layer to the metal substrate.

[0017] Also, where the decorative layer is a layer of material derived from various aggregate binder materials (e.g., cement, mortar, epoxy) mixed with a laser-reactive material (e.g., finely divided carbon), special configurations are created to produce cards with a top surface of the desired color and texture.

[0018] Also, various ceramic materials with selected textures and colors can be used to form a decorative layer bonded to the metal substrate.

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

[0020] Cards embodying the invention include a thin decorative layer and a thick core layer of metal, ceramic-coated metal, ceramic-coated polymer, or solid ceramic material. Additionally, cards can include multiple different polymer layers. Additionally, metal cards embodying the invention can include an integrated circuit chip and an antenna that allows RF transmission of signals between the card and the card reader. These cards are "smart" cards that can function as contact cards and / or dual interface (contact and / or contactless).

[0021] Additionally, cards embodying the invention include pockets formed in the top surface of the card that allow for placement of one or more decorative layers therein. [Brief description of the drawings]

[0022] In the accompanying drawings, which are not drawn to scale, like reference numbers indicate like elements. [Figure 1] 1 is a cross-sectional view of color layers combined to form a metal card having controlled color in accordance with the present invention; [Figure 1A] 2 is a cross-sectional view illustrating the removal of a top layer portion of the card shown in FIG. 1 showing different colors. [Figure 1B]FIG. 2 is a cross-sectional view showing the removal of two top layer portions of the card shown in FIG. 1 showing even more color. [Diagram 2] 1 is a cross-sectional view of selected layers used to form a card having metal and polymeric layers embodying the present invention; [Diagram 3] 1 is a cross-sectional view of a dual interface smart card having a color layer, a metal layer, and a polymer layer embodying the present invention; [Figure 4] FIG. 4 is an exploded view of the layers and components of a card of the type shown in FIG. 3 (but omitting the adhesive layer). [Diagram 5] FIG. 1 is a cross-sectional view of a card including an embossable layer of a thermoset polymer layer adhered to an anodized aluminum foil layer. [Figure 5A] FIG. 6 is a cross-sectional view of a surface embossed card of the type shown in FIG. 5. [Figure 6] FIG. 2 is a top view of a card having four color layers for forming a card according to the present invention. [Figure 6A] FIG. 7 is a cross-sectional view of the card shown in FIG. 6. [Figure 6B] FIG. 1 is a cross-sectional view illustrating that an anodized aluminum layer 14 having multiple color levels can be formed. [Figure 7A] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural wood veneer according to the present invention; FIG. [Figure 7B] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural wood veneer according to the present invention; FIG. [Figure 7C] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural wood veneer according to the present invention; FIG. [Figure 7D] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural wood veneer according to the present invention; FIG. [Figure 7E] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural wood veneer according to the present invention; FIG. [Figure 8A]10A-10C are cross-sectional views illustrating a portion of a process for forming a metal card having a veneer of cement in accordance with the present invention. [Figure 8B] 10A-10C are cross-sectional views illustrating a portion of a process for forming a metal card having a veneer of cement in accordance with the present invention. [Figure 8C] 10A-10C are cross-sectional views illustrating a portion of a process for forming a metal card having a veneer of cement in accordance with the present invention. [Figure 8D] 10A-10C are cross-sectional views illustrating a portion of a process for forming a metal card having a veneer of cement in accordance with the present invention. [Figure 9A] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural leather veneer in accordance with the present invention; [Figure 9B] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural leather veneer in accordance with the present invention; [Figure 9C] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural leather veneer in accordance with the present invention; [Figure 9D] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural leather veneer in accordance with the present invention; [Figure 9E] 1 is a cross-sectional view showing a portion of a process for forming a metal card having a natural leather veneer in accordance with the present invention; [Figure 10A] FIG. 2 is a top view of a pocket formed on the top surface of a metal substrate. [Figure 10B] FIG. 10B is a cross-sectional view showing a decorative layer adhered to the pocket of FIG. 10A. [Figure 10C] FIG. 13 is a cross-sectional view showing an additional layer adhered to the bottom surface of the metal substrate. [Figure 10D] FIG. 7A is a top isometric view of a metal substrate with a pocket formed therein for placing a decorative layer therein, which may be, for example, an anodized metal layer or any veneer layer, as shown in FIG. 7A, FIG. 8A, or FIG. 9A; [Figure 10E] FIG. 10E is a top isometric view of the card of FIG. 10D having a decorative layer inserted into a pocket and adhered to a metal substrate. [Figure 11] FIG. 2 is a highly simplified cross-sectional view showing decorative layers adhered to the top and bottom surfaces of a metal substrate. [Figure 11A] A cross-sectional view showing that the decorative layers attached to the top and bottom surfaces of the metal substrate may be different. [Figure 11B] A cross-sectional view showing that the decorative layers attached to the top and bottom surfaces of the metal substrate may be different. [Figure 11C] A cross-sectional view showing that the decorative layers attached to the top and bottom surfaces of the metal substrate may be different. [Figure 11D] FIG. 2 is a cross-sectional view showing a ceramic layer and a decorative layer bonded to the top and bottom surfaces of a metal substrate. [Figure 11E] FIG. 2 is a cross-sectional view of a metal card having a ceramic decorative layer to which a laser light source is applied to modify the appearance and texture of the card. [Figure 11F] FIG. 2 is a cross-sectional view showing one type of thin decorative layer (anodized aluminum) adhered to the top and bottom surfaces of a metal substrate according to the present invention. [Figure 12] FIG. 13 is a cross-sectional view of a card having an optional polymer layer adhered to the bottom surface of a decorative layer. [Figure 12A] FIG. 1 is a bottom view of a signature panel and magnetic stripe adhered to the bottom surface of a polymer layer or anodized aluminum foil. [Figure 12B] FIG. 1 is a bottom view of a signature panel and magnetic stripe adhered to the bottom surface of a polymer layer or anodized aluminum foil. [Figure 13A] FIG. 1 is a cross-sectional view of a card having a colored anodized aluminum foil bonded to a metal substrate in accordance with the present invention. [Figure 13B] FIG. 2 illustrates some of the steps of a process for forming a card according to the present invention. [Figure 13C] 13B is a cross-sectional view illustrating the formation of a pattern in the anodized aluminum oxide layer of FIG. 13A. [Figure 13D] FIG. 13B is a cross-sectional view illustrating the results of electroplating a pattern formed in the anodized aluminum oxide layer of FIG. 13A with a noble metal. [Figure 14]FIG. 2 is a cross-sectional view of a card having a ceramic core and a decorative layer. [Figure 14A] FIG. 13 is an isometric top view of a pocket formed in a ceramic core layer. [Figure 14B] FIG. 14B is an isometric top view of a decorative layer adhered to the pocket of FIG. 14A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Metal card having at least one anodized layer FIG. 1 shows one embodiment of a metal-based transaction card 10 having multiple different colored layers. In FIG. 1, card 10 includes a colored hardcoat top layer 12 overlying an anodized aluminum foil layer 14. Hardcoat layer 12 can be adhered to anodized layer 14 by any known or suitable method (e.g., by bonding, spraying thereon and curing, adhering via an adhesive or carrier layer, or transferring from a carrier sheet). Layer 14 is adhered to base metal layer 16 via adhesive layer 15. Layers 12 and 14 are designed with selected colors that are used to give card 10 different color and decorative appearances. The colors of layers 12 and 14 can be combined with the color of base metal layer 16 to provide the card with an even wider range of colors and decorative patterns.

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

[0025] Layer 12 provides a scratch resistant surface and may also provide a color layer. Hardcoat layer 12 may be formed from nanoparticles such as silicate nanoparticles, zinc oxide nanoparticles, silicon dioxide crystalline nanoparticles, or any other suitable nanoparticles with a suitable carrier such as solvent, water-based, or UV curable acrylate, vinyl, urethane, etc. The hardcoat may be applied by coating techniques such as spray, gravure, reverse roll, direct roll, slot coating, etc.

[0026] The hardcoat layer 12 can be applied to the card or to a subassembly used in forming the card using a special carrier layer. The special carrier allows the release layer and hardcoat layer to be adhered to the special carrier layer to form a subassembly, which can then be attached and transferred to another subassembly to form an intermediate assembly from which the carrier and release layer can be removed to leave the hardcoat layer as the top and / or bottom layer of the card. The hardcoat layer can be clear or colored. Color is added to the hardcoat layer by adding a pigment or dye to the adhesive layer or by mixing with the hardcoat vehicle itself.

[0027] The second layer 14 consists of a colored anodized metal layer shown adhered to a base metal layer 16 via an adhesive layer 15. This layer 14 can also be bonded and laminated to the undercoat layer 16. The anodized metal layer 14 is shown to be made of aluminum. However, the anodized layer 14 can be titanium, zinc, niobium, tantalum, or other metals that can be anodized. In the present invention, the anodized layer can be further modified by (a) dyeing the anodized layer with one or more colors, or (b) printing graphics via techniques such as screen printing, dye sublimation printing, or any digital printing system. The anodized metal layer 14 can be further modified by techniques such as laser engraving, machine engraving, die cutting, or embossing. The anodized metal layer can be used on the card as a full surface material (i.e., extending the entire length and width of the card), patches, stripes, or other decorative designs.

[0028] The use of a colored anode layer 14 instead of a polymer layer over a colored metal layer 16 provides greater flexibility and cost savings. The use of a printed anode material instead of a polymeric material overcomes the challenges that exist when using polymers because metals are denser than polymers and do not have minimum print thickness limitations. The composition and method can be used with all types of transaction and ID cards, including contactless, contact, and dual interface smart cards.

[0029] The base or substrate metal layer 16 used in cards embodying the invention may be stainless steel, bronze, copper, titanium, or any suitable metal that provides the card with the majority of its body (structure) and weight.

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

[0031] In Figures 1, 1A and 1B, a laser 101 is shown for applying a laser beam to a card 10. The power level of the laser 10 is controlled by a power controller 103. Controlling the power level of the laser allows for the production of cards whose color can be varied and controlled. The laser can be used to ablate selected portions of the hard coat layer 12 and the anodization layer 14. Furthermore, the laser can be used to vary the color of the base metal layer 16 by controlling (changing) the power level and polarization of the laser (e.g., this may be called a type of diffractive laser). In this way, the color and texture of each card can be controlled and varied.

[0032] 1A shows that the desired color contrast can be created by selectively laser ablating or engraving the top layer 12 to reveal the second layer 14. This can be achieved by specific optimized laser parameters or engraving techniques.

[0033] 1B shows that a second set of parameters can be used to remove selected portions of the anode layer 14 below the base metal 16. This allows for multi-color gradations on the metal card, which may include the base metal finish itself. This aesthetic appearance is highly desirable in the marketplace.

[0034] Note that only a single anodized layer is shown in the figure, however, more than one (i.e., multiple) anodized layers of a suitable metal could be used, for example, there would be one anodized layer per piece of aluminum, and thus multiple layers of aluminum.

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

[0036] Wireless, contact or dual interface cards FIG. 3 is a cross-sectional view of a hybrid dual interface metallic smart card with a colored layer embodying the invention, and FIG. 4 is an exploded view of the layers and components of a card of the type shown in FIG. 3 (but omitting the adhesive layer). FIGS. 3 and 4 show that cards of selected textures and colors embodying the 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 a module antenna 112 for RF (radio / contactless) transmission. The 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 contacting a reader. The module 109 and its IC 110 can be used as part of the contactless (wireless) system of FIG. 1 and / or as a direct contact system and / or as a dual interface (contact and / or contact) system. In FIG. 3, card 10 includes a ferrite layer 20 adhered to the underside of metal layer 16 via 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 prevent metal layer 16 from attenuating incoming and outgoing RF signals, allowing RF transmission between a card reader (not shown) and chip 110. The top layer of the card has a cutout to allow module 109 to fit in. Polymer layer 18 may include a magnetic stripe and signature panel, or additional layers 24 may be adhered to layer 18 to provide these functions. With the addition of colored hard coat layer 12 and anodized metal layer 14, a "smart" dual interface metal-hybrid card formed as shown in FIG. 3 and FIG. 4 may be made to have the desired color and texture characteristics and function as any regular smart hybrid or metal card.

[0037] 5 and 5A are cross-sectional views of a card similar to that shown in FIG. 2, but which further includes an embossable copolymer layer 24 (identified in the figures as a polyester layer) formed on anodized aluminum film layer 14. Card 10 can be formed by assembling layers 12, 24, 14, 16, and 18 and adhering the layers by bonding and / or using adhesive layers 15, 17, 23, as shown in FIG. 5. The assembly can then be laminated and embossed by an embossing process, and plates 55a, 55b can be laminated to produce an embossed image on the top layer, or on the other top layers 24 and 14, as shown in FIG. 5 (layer 12 is optional and may not be used on all cards). Thus, FIGS. 5 and 5A show how embossing can be used to control and modify the color and texture of a card.

[0038] Alternatively, the embossing layer 24 may be a curable polymer, to which an adhesive layer is then adhered. The hardcoat layer 12 may be placed on the embossing layer before or after the embossing step. During lamination, the embossing plate 55a may be used to emboss the desired image into the copolyester layer 24 (layer 24 may be any embossable polymer), and also emboss the anodized metal layer 14 underneath. The copolyester layer 24 (as well as the hardcoat layer) provides a scratch-resistant layer, and the embossing provides a tactile component that is desirable for the industry; that is, the embossed surface may give the card a textured feel. The hardcoat 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 texture features. By way of example, top layer 12 may be a black hard coat layer that can provide a background that is more scratch resistant and less expensive than PVD. A second layer 14 of anodized aluminum adhered to layer 12 may be colored pink. A third metal layer 16 adhered to layer 14 is colored gray. A fourth layer 161, typically a thin plastic (but may also be a metal layer) adhered to layer 16, is colored silver. The laser source 101 can be used to create textured and controlled color cards. A first set of laser settings removes selected portions of the hard coat layer 12 to expose the anodized layer underneath. 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 produce the silver feature of layer 161. Intermediate gradients can be created by partially removing each layer, opening up a variety of 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 multicolored layer. Different colors can be introduced into different sub-segments (sub-layers) of the aluminum layer during the anodization process. Different colors can be displayed by laser machining down different sub-layers of layer 14 to display different color levels. Various colors can be displayed by mechanical engraving or other material removal means instead of laser machining. Additional layers can also be colored hard coat layers alone or in combination with the metal layers.

[0041] As noted above, cards embodying the invention may be formed by first assembling selected polymeric and metallic layers and bonding or adhesively adhering them together, as shown in Figures 1, 2, 3, 5, and 6. The various layers are laminated at temperatures typically ranging from 200°F to 500°F, with effective pressures of 50 to 500 PSIA. Typically, a first set of optimized laser or mechanical engraving parameters is used to remove the colored transfer hardcoat (e.g., 12) to reveal the underlying colored anodized layer. A second set of optimized laser or mechanical engraving parameters is then used to remove portions of the colored anodized layer (14) to expose the metal underneath. In the case of Figures 6 and 6A, a third set of optimized laser or mechanical engraving parameters may 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 making the card, the card is cut to size and final processing such as hot stamping is completed.

[0042] Thus, an anodized aluminum layer is used as a thin decorative layer (see DLa, DLb in FIG. 11). In one embodiment of the present invention, the thin decorative layer comprises at least one anodized metal layer to add color and / or texture to the card. The card can also comprise 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. Various controlled laser output devices (or any similar functional device) can be applied to the laminated card to remove selected portions of the different layers, thereby modifying the displayed color and pattern and texture of the card.

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

[0044] Cards with decorative panels FIG. 7 shows the production of a "textured" metal card with a thin decorative layer selected to be an actual wood layer placed on the top surface of the card. Note that the use of "wood" is merely exemplary and is meant to include any material derived from a (living) plant that has similar properties 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 is virtually impossible to replicate and represents a high level of individuality. However, there are significant problems in maintaining the texture and appearance of the actual wood layer used to form the card. These are overcome in the production of cards according to the present invention.

[0045] With reference to FIG. 7, the following procedure or steps can be used. 1. A low lignin natural wood veneer layer 700 is selected as shown in Figure 7 A. By using a wood layer with low lignin content, it is easier to maintain the appearance of the wood layer through the various lamination and processing steps to form the card.

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

[0047] 3. As shown in Figure 7C, form an assembly 750 including a treated wood layer 700 adhered to a metal substrate 16 with adhesive 15a. Adhesive layer 15a may include an acid modified polyolefin or any suitable adhesive. Typically layer 700 will have a thickness in the range of 0.001 inch to 0.014 inch and metal layer 16 will have a thickness in the range of 0.005 inch to 0.032 inch.

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

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

[0050] 6. Bevel the wood layer 700 as shown in FIG. 7E to cut away any right angle edges or corners, creating symmetrical beveled edges and minimizing issues with frayed or peeled edges of the card.

[0051] Cards with cement veneer FIG. 8 shows the production of a "textured" metal card with a thin decorative layer selected to be a veneer layer 800 of aggregate binder material. 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 mentioned above, the cement may be of another material as mentioned. The use of a cement layer provides a unique tactile sensation. However, there are significant problems in producing cards with a particular texture and color, maintaining the texture, and providing images with a high level of contrast. These are overcome in the production of these cards according to the present invention.

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

[0053] 1. As shown in FIG. 8A, a cement layer 800 is formed from a cement mixture to which a carbon material (eg, carbon soot) has been added to produce a greyish 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. Laser the cement layer using laser device 101 to create the desired pattern (area 804) as shown in Figure 8B. Laser 101 vaporizes carbon particles in the selected areas, creating a white pattern that contrasts with the gray background. 4. The laser irradiated cement layer 800 can then be adhered to a metal substrate 16 via a suitable adhesive layer 15b to form an assembly 850 as shown in Figure 8C. 5. Instead of step 3 above, a non-laser irradiated cement layer 800 may be first adhered to the metal substrate 16 and then irradiated with the laser. 6. Figure 8D shows that layer 800a can be formed using an epoxy material mixed with carbon particles. Layer 800a can be directly bonded to metal substrate 16. Layer 800a can be subjected to laser irradiation before or after being bonded to metal substrate 16. The use of an epoxy material eliminates the need for an additional adhesive layer and provides a very strong bond between epoxy layer 800a and the underlying metal substrate 16 (which can be, for example, steel or other suitable metal).

[0054] Cards with leather veneer FIG. 9 illustrates the production of a "textured" metal card with a thin decorative layer selected to be a real leather veneer layer placed on the top surface of the card. Note that similar animal-derived materials may be used instead. As with "natural" or "real" wood layers, the use of a real leather layer is important because it has many unique properties; namely, the grain and richness of the appearance and pattern displayed by a real leather layer is virtually impossible to replicate and represents a high degree of individuality. However, there are significant problems in maintaining the texture and appearance of the "natural" leather layer used to form the card. These are overcome in the production of cards according to the present invention.

[0055] Referring to FIG. 9, the following operations or steps can be used to form the cards. 1. As shown in Figure 9, there is a selection step: Select a layer of natural leather 900 having a natural unique pattern on its upper surface 901. 2. Next there is leather processing or treatment to prepare the underside 903 of the leather layer 900 so that the leather layer has the desired thickness and the bottom surface is adapted to accept an adhesive. A typical thickness would be in the range of 0.003 to 0.014 inches, although this can be thinner or thicker. 3. Next comes the embossing step, as shown in Figure 9B: The top surface 901 of the first leather layer 900 is embossed with the desired pattern. 4. The highly novel feature used to laminate the leather layer 900 to the underlying metal substrate 16 also allows for the creation of a mirror image of the embossed pattern. It is extremely important that the lamination process to secure 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 accomplished as follows: An assembly 910 is formed as shown in Figure 9C, which shows: a. an embossed first leather layer 900 adhered to a metal substrate layer 16 via an adhesive layer 15c; and A blank (non-embossed) leather layer 902 (i.e., second leather layer) is shown between the embossed leather layer 900 and the platen 75a, with the top surface facing the embossed surface 901 of the first leather layer 900. Layer 902 may be similar to 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. The assembly 910 undergoes a lamination step, as shown in Figure 9D. With the proper selection of layers 900 and 902 (and the proper lamination pressure), the lamination process will keep intact the features and patterns embossed in the first leather layer 900, producing an assembly or subassembly 950 as shown in Figure 9E.

[0057] 6. At the same time, the embossed pattern is transferred (as a mirror image) to the top surface 911 of a second leather layer 902, which can then be used to emboss a subsequent leather layer as shown in Figure 9E, or a similar layer. This is important in that the "unembossed" leather layer (e.g., 902) becomes the 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 veneer layer can be subject to fraying and peeling. One approach to avoid this problem is to chamfer the edges of the veneer layer as shown in FIG. 7E. Another approach is to form a pocket 981 on the top surface of the metal card as shown in FIG. 10. FIG. 10A is a top view of a card with cutouts 981 for forming a pocket on the top surface of the card. The pocket can be formed using any known technique. Edges d1 and d2 can range from 0.01 to 1.125 inches and can be uneven or form an aesthetic pattern. FIG. 10B is a cross-sectional view showing that anodized aluminum layer 14 or any veneer layer (e.g., 700, 800, 900) can be adhered to the top inner surface of the pocket 981 of the card cut out from the core metal layer 16 via a suitable adhesive 15c. This configuration is elegant and prevents the edges of the anodized layer or veneer layer from fraying, wearing, or peeling.

[0059] FIG. 10C shows that a polymeric, aluminum, or ceramic layer can be adhered to the underside of a metal substrate.

[0060] FIG. 10D is an isometric plan view of the metal layer 18 with a pocket 981 formed therein. For illustrative purposes, the pockets are shown not to be symmetrically arranged. The pocket 981 can be a small or large portion of the card surface with regular or irregular borders. FIG. 10E shows that an optional decorative layer (DL) can be adhered to or formed within the pocket 981. This includes an anodized aluminum layer, the various veneer layers mentioned above, as well as other decorative veneer layers or substances. This includes, as an example, a product currently on the market called Swarovski Elements Crystal Fabric. This material includes a carrier material completely covered with millions of small cut round crystals. It is elastic, tear-resistant, and extremely light. This carrier material features a low-temperature characteristic adhesive, so it can be applied to various surfaces by low-temperature heating. This adhesive can be replaced with a stronger adhesive for more severe environments.

[0061] In other embodiments of the invention, small pockets of very limited area (e.g., a small portion of the surface area of ​​the card) having virtually any shape can be formed within the card for containing decorative material therein.

[0062] The above is by way of example, and generally, the present invention describes various methods and apparatus for preparing thin anodized metal layers and / or selected thin laminate layers for attachment to thick metal substrates to produce cards having desired color and texture characteristics.

[0063] As shown in Figure 11, a metal card embodying the invention can be formed to include a core metal layer 16 having a decorative layer (DLa) on top of the metal layer 16 and a decorative layer (DLb) below the metal layer. Each of the decorative layers DLa and DLb can 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 identified in a-f above, and the other decorative layer (e.g., DLb) can be DLa or a different one of the layers identified in a-f.

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

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

[0066] 11C, anodized aluminum foil 14a is adhered to one side (top) of a metal substrate 16 via adhesive 15, and a ceramic veneer layer 990 is adhered to the other side (bottom) of the metal substrate. Signature panel 123 and magnetic stripe 125 are shown adhered to ceramic layer 990.

[0067] 11B and 11C show that the decorative veneer layer can be a layer of ceramic material 990. Ceramic materials have highly desirable properties because they can be made to have virtually any color and can adhere (bond) to the metal substrate without the use of adhesives. The layer of ceramic material can be applied (e.g., sprayed) directly to the metal substrate 16 and then fired or cured on the metal 16. Furthermore, FIG. 11B and 11C show that one of the decorative layers can be a veneer layer of one type (leather, anodized aluminum) and the other decorative layer can be a different type (e.g., ceramic).

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

[0069] 11E shows a laser source 101 that can be used to laser engrave a decorative ceramic layer 990a bonded to the top surface of a metal substrate 16 having a similar or different decorative layer DLb bonded to the bottom surface of 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 desired aesthetic effects.

[0070] 11F shows a metal substrate 16 having anodized aluminum foil 14a bonded to its top surface and anodized aluminum foil 14b bonded 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. The card has an anodized aluminum layer 14a adhered to one side (top of the figure) of a metal substrate 16 via adhesive 15, and another anodized aluminum layer 14b adhered to the other side (bottom of the figure) of the metal substrate via adhesive 17. Anodized layers 14a and 14b are decorative layers adhered to metal layer 16. A polymer layer 121 is shown adhered to the bottom side of layer 14b. As shown in FIG. 12A, layer 121 may be a clear polymer layer so that the color and decorative features of layer 14b can be displayed and viewed. 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 Figure 12B, the bottom layer of the card may be layer 14b (i.e., no polymer layer is used). In a particular embodiment, applicants have used a thermosetting type adhesive to bond the signature panel 123 and magnetic stripe 125 directly to the anodized aluminum layer 14b.

[0073] Figure 13A shows the colour and decorative features of a card embodying the invention. In Figure 13A the anodised top layer 14a has an upper region 141 which is coloured blue as an example. The thickness of region 141 may range from less than 0.1 microns to more than 5 microns (although it should be understood that this is a wide variation). Layer 14a is adhered via adhesive layer 15 to a core metal substrate 16 which is in turn adhered via adhesive 17 to a decorative layer DLb which may be any of the layers of types (a)-(f) described above.

[0074] As shown in FIG. 13B, after the layers shown in FIG. 13A are assembled (see box 1041), a pattern can be formed by removing selected portions of the anode material in region 141 (see box 1042), leaving the underlying uncolored aluminum foil; i.e., the portion of layer 14 or 14a below region 141. The removal of material in region 141 can be done by a laser or any other suitable means. For example, if a laser is used, the laser simply removes 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. The laser-irradiated assembly can then be subjected to an electroplating process (see box 1043) using a metal such as gold or any suitable metal to electroplate a selected metal onto or within the pattern formed in anode region 141. The pattern formed can have the appearance shown in FIG. 13D. As shown in box 1044, the card can be further processed (completed) to include any and all additional features to form all types of cards as described above.

[0075] Ceramic Card FIG. 14 shows that a card 10a can be formed with a ceramic core 131, which can be designed to provide a predetermined color. A decorative layer DLa can be attached to the top side of the ceramic core and / or another decorative layer DLb can be attached to the bottom side of the core layer. The decorative layer DLa can 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 placement therein of a decorative layer (DL) as shown in FIG. 14B. The decorative layer can be any layer of the types mentioned above or any other suitable material. Ceramic materials are inorganic non-metallic materials made from compounds of metals and non-metals. Ceramic materials can be crystalline or partially crystalline. They are formed by the action of heat and subsequent cooling. Ceramic materials tend to be strong, hard, brittle, chemically inert, and non-conductors of heat and electricity.

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

[0077] Solid ceramic cards can be made by injection molding to form the desired shape and then sintering to create a standard size with nominal dimensions (3.37" x 2.125" x 0.03", but not limited to a particular size). Pockets that allow for 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. Ceramic card bodies can also be made from larger ceramic blocks and machined to the desired size, and ceramic parts may be 3D printed for fabrication. In a preferred embodiment, the ceramic can include sintered zirconium dioxide, but may also include one or more oxides such as, but not limited to, alumina, beryllium, ceria, ceramides, carbides, borides, nitrides, or silicides.

[0078] Solid ceramic cards offer functional advantages over existing premium metal cards in that they do not need to be specially machined, do not generate static discharge, and do not interfere with RF radiation for contactless transactions. Aesthetically, solid ceramic cards can be obtained in a variety of colors by adding pigments to the ceramic compound, can be varied by laser marking, and can be further modified by the addition of 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 engraving, or any method known in the art.

[0079] As shown in Figures 11B, 11C, 11D, and 11E, a transaction card can also be provided that includes a metal-ceramic composite material that contains metal and ceramic. In some embodiments, a ceramic insert can be placed in a metal and metal plastic card to create unique features and enhance available color, texture, and laser features while maintaining most of the weight of a metal card. For example, such an insert can be attached by machining a pocket in the core, placing an adhesive in the pocket, and adhering the ceramic insert in the pocket. In another embodiment, the ceramic insert and the created pocket can each be configured such that the ceramic insert is held in place by a press fit. In yet another embodiment, the core can have one or more tapped holes located on its edges such that the core acts as a frame and set screws located in the tapped holes hold the ceramic insert in the frame. However, adhering the ceramic insert to the core is not limited to a particular method.

[0080] Metal core cards with double and single sided ceramic coatings may be provided (see Figures 11B, 11C, 11D, and 11E). The metal core may comprise a solid metal of 0.024" to 0.030" (but not limited to any particular thickness), including but not limited to brass, steel, nickel, palladium, silver, gold, platinum, aluminum, or other suitable metals or metal alloys known in the art. The metal core may also comprise a composite structure, such as a core containing a first metal of 0.001" to 0.029" (but not limited to any particular thickness) bonded to a second metal of 0.001" to 0.029" (but not limited to any particular thickness), or any multiple layers that make up 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 composite metals may also be cost effective. A metal-plastic composite card with a single and double sided ceramic coating may achieve a desired manufacturing cost, weight, and aesthetic effect.

[0081] In one exemplary embodiment, a 0.02 inch thick metal core (e.g., steel) can be bonded to a 0.007 inch thick layer of PVC on one side with a ceramic coating on the non-bonded 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" to 0.003" thick, depending on the desired appearance of the coating. These coatings can be produced in a variety of colors. Typically, the coating consists of ceramic particulates containing zirconium dioxide, aluminum silicate, and a hardenable resin binder suspended in a volatile organic carrier solution, such as CERAKOTE® Ceramic Coating from NIC Industries, Inc. Once sprayed and cured, the coating provides the card with a unique color and texture with a very durable finish that typically reaches thousands of Taber abrasion cycles. The ceramic coating can be modified using mechanical or chemical engraving, inkjet printing, laser marking, and other methods known in the art to provide desired aesthetic effects, including designs on the card shown, for example, in FIG. 11E. Magnetic stripes, signature panels, branding, holograms, 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, such as by mechanical or laser engraving (see FIG. 10C), to bond such features to the metal core.

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

[0083] 2. Adding fastening means to the metal core, such as fasteners and fasteners that are used to hold the sheet in place while the next step is carried out.

[0084] 3. Creating surface features such as pockets to hold booster antennas used in conjunction with RFID chips that may be placed under the ceramic layer. Also, pockets are provided in the core that will ultimately become depressions in the ceramic coating where components (e.g. RFID chips) will later be bonded 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. Ceramic coating on one or both sides.

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

[0088] 7. The sheets are cut into card blanks using a CNC (computer numerical control) machine or similar.

[0089] 8. Apply functional and security features (magnetic stripe, chip, hologram, etc.) to the individual card blanks. As noted above, such features may be placed in pockets created earlier in the process or may be glued onto roughened areas. However, it is preferred that the magnetic stripe be applied directly onto the ceramic coating, as it is advantageous to apply it to as planar and flat a surface as possible.

[0090] In the market for identification cards that are traditionally constructed of composite plastics or polycarbonates, ceramics offer new possibilities to extend the life of the card and make it more difficult to counterfeit. Colored and clear ceramic coatings can be applied to a plastic core to create a material that is significantly more durable when tested by ISO standard flexibility and abrasion tests. Furthermore, these materials are much harder to counterfeit and allow for unique laser marking properties as well as the inclusion of unique phosphors in the ceramic to shift the incoming light up or down, creating a unique thin "watermark" as part of the ID. Some of the embodiments of the present invention are described below in items [1]-

[57] . [1] 1. A method of producing 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; selecting a thick core layer to form a 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 one another, the thick core layer being (a) a metal thick core layer, or (b) a ceramic-coated metal, or (c) a ceramic-coated polymer, or (d) a solid ceramic material; and adhering the thin decorative layer to a 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 being an anodized aluminum layer designed to have a predetermined color; 2. The method of 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 being an anodized aluminum layer having a predetermined color; forming a hard coat layer on the anodized aluminum layer; 2. The method of 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] 4. The method of claim 3, wherein the hard coat layer is designed to have a color different from that of the anodized aluminum. [5] 3. The method of claim 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 3. The method of 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 said anodized aluminum layer; 3. The method of claim 2, further comprising the step of embossing the polymer layer and the anodized aluminum layer. [8] the thick core layer being a thick metal layer and the thin decorative layer being an anodized aluminum layer designed to have a predetermined color; The thick metal layers are designed to have different colors; further comprising at least one additional layer having a preselected color; 2. The method of claim 1, further comprising 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 feel of the card. [9] The plant-derived material decorative board layer is a layer of natural wood having a low lignin content; 2. The method according to claim 1, wherein the processing of the wood veneer layer includes the steps of: (a) sanding the back side of the wood layer until the wood layer has a thickness in the range of 0.001 inch to 0.015 inch; and (b) applying an oil film to the wood layer to maintain its appearance when the wood layer is laminated.

[10] 10. The method of claim 9, further comprising the step of chamfering the outer edges of the wood layer to prevent fraying or peeling of the wood layer.

[11] the animal-derived material veneer layer is a layer of natural leather having a top surface and a bottom surface; 2. The method of claim 1, wherein the processing of the leather veneer layer includes treating a 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 the bottom surface is adapted to receive an adhesive.

[12] embossing the top surface of the leather layer; forming a first assembly comprising said skin layer having a bottom surface bonded to a first surface of said thick core layer.

[13] the thick core layer is a thick metal layer and the embossed leather layer is a first leather layer; forming a second assembly including positioning a second leather layer having a top surface and a bottom surface, the top surface of the second leather layer facing the top surface of the first embossed leather layer of the first assembly; 13. The method according to claim 12, further comprising the step of laminating the first and second leather layers and the thick metal layer, so that 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 laminate layer of aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material; 2. 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] 2. The method of claim 1, wherein the step of adhering the thin decorative layers to the thick core layer comprises forming a pocket in a surface of the thick core layer and firmly adhering one of the thin decorative layers within the pocket.

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

[17] the thin decorative layer being an anodized metal layer, 2. The method of claim 1, further comprising the step of dyeing the anodized metal layer a plurality of colors.

[18] the thin decorative layer being an anodized metal layer, 2. The method of claim 1, further comprising the step of modifying the anodized layer with one of the following printed graphics by techniques such as screen printing, sublimation printing, any digital printing system, laser engraving, mechanical engraving, die cutting, or embossing.

[19] the thin decorative layer being an anodized metal layer, 2. The method of claim 1, wherein the anodized metal layer is selectively extended along the surface of the card (a) the entire length and width of the card, (b) as patches, (c) as stripes, or (d) as a decorative design.

[20] 2. The method of claim 1, further comprising adhering a thin decorative layer to a second surface of the thick metal layer. [twenty one] 21. The method of claim 20, wherein the thin decorative layer adhered to the second surface of the thick metal layer comprises 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. [twenty two] the thick core layer is a thick metal layer; the thin decorative layer being a layer of ceramic material; 2. The method according to claim 1, wherein the step of selecting and processing the thin decorative layer comprises applying the ceramic layer to the thick metal layer and bonding it to the thick metal layer. [twenty three] the thin decorative layer being a thin anodized metal layer having a predetermined colored area extending to a predetermined depth within the thin metal layer; 2. The method of claim 1, further comprising the steps of: (a) removing selected portions of the colored area 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 area to produce a pattern displaying the electroplated metal and the color of the predetermined colored area. [twenty four] the thin anodized metal layer being a thin layer of aluminum having an area of ​​an upper sub-layer dyed to have the predetermined color; removing the selected portions of the colored areas includes exposing the selected portions of the anodized aluminum layer using a laser instrument; 24. The method of claim 23, wherein the electroplated metal is a precious metal such as gold. [twenty five] 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, said thick core layer forming the bulk of the card and having a predetermined color, said thick core layer having first and second surfaces extending generally parallel to one another; The card includes a thin decorative layer adhered to a first surface of the thick core layer to provide 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 0.03 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.

[26] the thick core layer is a thick metal layer; the thin decorative layer being an anodized aluminum layer designed to have a predetermined color and having a pattern formed within the anodized layer to display the color of the anodized aluminum and the underlying thick metal layer; Item 26. The card according to item 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 being 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; Item 26. The card of item 25, wherein the anodized aluminum layer produces a pattern exhibiting 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 being 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 different color than the other layers of the card; a pattern is formed in the hard coat layer and the anodized aluminum oxide layer; 26. The card of claim 25, wherein the thick metal layer creates a pattern displaying 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; 26. The card of claim 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; Item 26. The card of item 25, further comprising: (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.

[31] the thick core layer is a thick metal layer; further comprising an embossable polymer layer adhered to said anodized aluminum layer; Item 26. The card of item 25, wherein a pattern is embossed into the polymer layer to produce a corresponding pattern that can be felt.

[32] the thick core layer is a thick metal layer; the thin decorative layer being an anodized aluminum layer designed to have a predetermined color; The thick metal layers are designed to have different colors; further comprising at least one additional layer having a preselected color; 26. The card of item 25, wherein selected portions of these layers are removed by one of laser irradiation, mechanical processing, or chemical etching such that the appearance correlates with the color of these layers and the texture of the card correlates with the formed pattern.

[33] The plant-based material veneer layer is a layer of real wood having a low lignin content; the wood layer having a thickness in the range of 0.001 inches to 0.010 inches; 26. The card of claim 25, wherein the layer of real wood has an upper surface protected by an oil film disposed along the upper surface.

[34] Item 34. The card according to item 33, wherein the outer edges of the wood layer are chamfered to prevent fraying or peeling of the wood layer.

[35] the thick core layer is a thick metal layer; the animal-derived material veneer layer is an actual leather layer having a top surface and a bottom surface, the top surface having a unique pattern associated with actual leather; the leather veneer layer having a thickness in the range of 0.001 inches to 0.020 inches; a bottom surface of the leather layer is modified and treated to accept adhesive; 26. The card of item 25, wherein the top surface of the leather layer is embossed and its bottom surface is adhered to the thick metal layer via an adhesive layer.

[36] the laminate layer of aggregate binder material is a layer of cement or epoxy mixed with a laser-reactive material; Item 26. The card of item 25, wherein a pattern is formed in the decorative laminate layer by vaporization of carbon particles.

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

[38] the thick core layer is a thick metal layer, and the thin decorative layer adhered to a first surface of the thick metal layer is a first thin decorative layer; 26. The card of item 25, wherein a second, thinner decorative layer is adhered to a second surface of the thicker metal layer.

[39] Item 39. The card of item 38, wherein 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 cloth material.

[40] Item 39. The card of item 38, wherein the thin decorative layer adhered to a first surface of the thick metal layer is different from the thin decorative layer adhered to a second surface of the thick metal layer.

[41] the thick core layer is a thick metal layer; a pocket is formed in a first surface of the thick metal layer; 26. The card of claim 25, wherein a thin decorative layer is adhered to the thick metal layer within the pocket.

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

[43] the second thin decorative layer is an anodized metal foil; Item 39. The card of 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; Item 39. The card of 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] 26. The card according to item 25, the thin decorative layer being a thin anodized metal layer having a predetermined colored area extending to a predetermined depth within the thin anodized metal layer; Selected portions of the colored area are removed to the predetermined depth according to a design pattern; The above card, wherein a particular metal having a color other than the predetermined colored areas is electroplated into the removed selected areas to produce a pattern representative of the particular metal and the color of the predetermined colored areas.

[46] Item 46. The card of 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 particular metal is a precious metal such as gold.

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

[48] Item 26. The card of item 25, wherein the thick core layer is a thick metal layer, a first ceramic layer is bonded to a first surface of the thick metal layer, and a second ceramic layer is bonded to a second surface of the thick metal layer.

[49] Item 26. The card of item 25, wherein the thick core layer is a thick ceramic layer.

[50] A metal card, a thick metal layer having a thickness ranging from 0.005 inches to 0.035 inches, said thick metal layer forming the bulk of said card and having a predetermined color, said thick metal layer having a top surface and a bottom surface; a pocket formed in a top surface of the thick metal layer, the pocket having a depth in the range of 0.003 inches to 0.030 inches below a boundary between a surface of the thick metal layer and around a periphery of the metal layer; a thin decorative layer adhered to a pocket formed in the top surface of the thick metal layer.

[51] the thin decorative layer having a thickness in the range of 0.005 inches to 0.030 inches; 51. The metal card of item 50, 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.

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

[53] Item 52. The card of item 51, wherein the veneer layer is one of wood, leather, ceramic, crystalline cloth material, cement, or epoxy.

[54] 1. A method of making a card, comprising the steps of: 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; forming a pocket in an upper surface of the thick metal layer, the pocket having a depth extending 0.003 inches to 0.030 inches below a boundary between the surface of the thick metal layer and around a periphery of the metal layer; and adhering a thin decorative layer to the pockets formed in the top surface of the thick metal layer to provide at least one of color and texture to the card.

[55] the thin decorative layer having a thickness in the range of 0.003 inches to 0.030 inches; Item 55. The metal card of item 54, wherein the thin decorative layer comprises 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.

[56] 1. A method of making a card, comprising the steps of: selecting a first layer of 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 second layer of leather-like material having a top surface and a bottom surface; forming an assembly including placing an upper surface of the second leather-like layer on an upper surface of the embossed first layer and overlying and adhering the first layer onto a metal substrate; laminating the assembly so as to laminate the embossed first layer with the metal layer to form a card or subassembly of a card, and simultaneously embossing the top surface of a second leather-like layer.

[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, said thick ceramic layer forming the bulk of said card and having a predetermined color, said thick metal layer having first and second surfaces extending generally parallel to one another; and a thin decorative layer adhered to a first surface of the thick ceramic layer to provide 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, 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.

Claims

1. A card, a metal layer forming the bulk of the card and having a first color or texture, the metal layer having a top surface and a bottom surface; a pocket formed in a top surface of the metal layer, the depth of the pocket extending below the surface of the metal layer; a boundary line around an outer periphery of the metal layer; a decorative layer adhered to a pocket formed in the upper surface of the metal layer; the decorative layer includes an anodized metal layer having a second color or texture and a hardcoat layer having a third color or texture formed on the anodized metal layer, thereby providing a pattern exhibiting a first color or texture, a second color or texture, and a third color or texture.

2. 2. The card of claim 1, wherein the decorative layer comprises: (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; (e) a ceramic layer; and (f) a layer of a crystal fabric material.

3. 2. The card of claim 1, wherein the anodized metal layer is one of aluminum, titanium, zinc, niobium, tantalum, or any other metal that can be anodized.

4. the decorative layer adhered to the pocket is a first decorative layer; The card of claim 1 further comprising a second decorative layer adhered to a bottom surface of the metal layer.

5. The card of claim 4 , wherein the second decorative layer comprises a ceramic material.

6. 5. The card of claim 4, wherein the decorative layer adhered to the pocket is different from the second decorative layer adhered to a bottom surface of the metal layer.

7. The card of claim 1 , wherein the decorative layer has a color or texture different from a color or texture of the metal layer.

8. The card of claim 1 further comprising a polymer layer adhered to a bottom surface of the metal layer.

9. 13. The card of claim 1, further comprising: an integrated circuit module located 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.

10. 2. The card of claim 1, wherein the metal layer has a thickness in the range of 0.005 inches to 0.035 inches, and the pocket has a depth extending 0.003 inches to 0.030 inches below the top surface of the metal layer.

11. The card of claim 10, wherein the decorative layer has a thickness in the range of 0.005 inches to 0.030 inches.

12. 1. A method of making a card, comprising the steps of: providing a metal layer having a first color or texture and having substantially parallel top and bottom surfaces; forming a pocket in an upper surface of the metal layer, the depth of the pocket extending below a surface of the metal layer and forming a perimeter around a perimeter of the metal layer; and adhering a first decorative layer to the pocket formed in the top surface of the metal layer to provide at least one of color and texture to the card; The method as described above, wherein the decorative layer comprises an anodized metal layer having a second color or texture and a hardcoat layer having a third color or texture formed on the anodized metal layer, thereby providing a pattern exhibiting a first color or texture, a second color or texture, and a third color or texture.

13. The method of claim 12, wherein the metal layer has a thickness in the range of 0.005 inches to 0.035 inches and the pocket has a depth extending 0.003 inches to 0.030 inches below a top surface of the metal layer.

14. The method of claim 13, wherein the first decorative layer has a thickness in the range of 0.003 inches to 0.030 inches.

15. 13. The method of claim 12, wherein the decorative layer comprises: (b) a laminate layer of a plant-derived material such as wood; (c) a laminate layer of an animal-derived material such as leather; (d) a laminate 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 fabric material.

16. The method of claim 12 further comprising adhering a second decorative layer to a bottom surface of the metal layer.

17. The method of claim 12 , wherein the first decorative layer has a color or texture different from a color or texture of the metal layer.

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