Ceramic-containing and ceramic composite transaction cards

Patent metadata

Field	Value
Publication number	US-11521035-B2
Application number	US-202016790868-A
Country	US
Kind code	B2
Filing date	Feb 14, 2020
Priority date	Nov 3, 2014
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

Abstract

A process for making a card includes the steps of forming a core layer having a first surface and a second surface, disposing an uncured decorative ceramic layer of ceramic particles disposed in a resin binder over the first surface of the core layer, such as by spray coating, and curing the uncured decorative ceramic layer to form a cured decorative ceramic layer. Card products of the process may have a core layer of metal, ceramic, or a combination thereof that form a bulk of the card.

First claim

What is claimed:

1. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer; and
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer;
wherein step (b) comprises spray coating the decorative ceramic layer over the first surface of the core layer.

2. The process of claim 1 , wherein the spray coating comprises a mixture comprising zirconia dioxide, aluminum disilicide, the pigment, and the binder suspended in a volatile organic carrier solution.

3. The process of claim 1 , further comprising the step of forming one or more pockets in the core layer or the cured decorative ceramic layer.

4. The process of claim 3 , comprising disposing a contact or DI chip module in the pocket such that an exposed outer surface of the contact or DI chip module is smoothly aligned with an exposed outer surface of the cured decorative ceramic layer.

5. The process of claim 1 , comprising forming at least one pocket in the core layer prior to performing steps (b) and (c).

6. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer;
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer; and
(d) forming at least one pocket in the core layer prior to performing steps (b) and (c);
wherein performing steps (b) and (c) results in a depression in the ceramic layer overlying the at least one pocket, and the process further comprises disposing a component in the depression such that the component and the cured decorative ceramic layer not overlying the pocket define a smooth surface.

7. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer;
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer;
(d) forming at least one pocket in the core layer prior to performing steps (b) and (c); and
(e) disposing a component in the pocket prior to performing steps (b) and (c), such that the component is disposed below the cured decorative ceramic layer after performing steps (b) and (c).

8. The process of claim 7 , wherein the component comprises a booster antenna.

9. The process of claim 1 , comprising forming said at least one pocket in the cured decorative ceramic layer after performing steps (b) and (c).

10. The process of claim 9 , comprising forming said at least one pocket having a depth that extends to said core layer, and securing a component to said core layer within said pocket.

11. The process of claim 1 , further comprising providing an artistic effect on the cured decorative ceramic layer by performing an engraving step, a printing step, or a laser marking step.

12. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer; and
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer; and
wherein step (c) comprises a thermal curing step.

13. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer; and
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer; and
wherein step (c) comprises an air-curing step.

14. The process of claim 1 , wherein step (c) comprises a UV curing step.

15. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer;
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer; and
(d) applying a surface finish to the first surface of the core prior to performing step (b).

16. The process of claim 1 , further comprising conducting at least steps (a)-(c) on a sheet comprising a plurality of cards, and then cutting the sheet into a plurality of card blanks.

17. The process of claim 1 , further comprising providing the card with one or more functional or security features.

18. The process of claim 17 , wherein the one or more functional or security features comprises a magnetic stripe, signature panel, or a hologram.

19. The process of claim 1 , further comprising laser-marking at least one feature on the cured decorative ceramic layer.

20. The process of claim 1 , further comprising removing a portion of the cured decorative ceramic layer to reveal a visible portion of a layer underlying the cured decorative ceramic layer.

21. The process of claim 1 , further comprising creating a design on or in the cured decorative ceramic layer comprising at least two colors or tones different than a color of the cured decorative ceramic layer.

22. A process for making a card, the process comprising the steps of:
(a) forming a core layer having a first surface and a second surface;
(b) disposing an uncured decorative ceramic layer, comprising ceramic particles disposed in a resin binder, over the first surface of the core layer;
(c) curing the uncured decorative ceramic layer to form a cured decorative ceramic layer; and
(d) creating one or more surface features on the first surface of the core layer prior to step (b), wherein the one or more surface features result in depressions in the cured decorative ceramic layer.

23. A card comprising a product of the process of claim 22 .

24. The card of claim 23 , wherein the visible portion revealed by the step of removing the portion of the cured decorative ceramic layer comprises a portion of the core layer.

25. The card of claim 23 , further comprising an intermediate layer having a desired color disposed between the core layer and the cured decorative ceramic layer, wherein the visible portion revealed by the step of removing the portion of the cured decorative ceramic layer comprises a portion of the intermediate layer.

26. The card of claim 23 , wherein one of the core layer, a layer between the core layer and the cured decorative ceramic layer, or a combination thereof, includes a first metal layer and a second metal layer, wherein the visible portion revealed by the step of removing the portion of the cured decorative ceramic layer comprises respective portions of the first metal layer and the second metal layer.

27. A card comprising a product of the process of claim 1 .

28. The card of claim 27 , wherein core layer comprises metal, ceramic, or a com

Assignees

• Composecure Llc

Inventors

• Herslow John
• Lowe Adam J

Classifications

• B32B27/18

  characterised by the use of special additives · CPC title

• B32B2363/00

  Epoxy resins · CPC title

• B32B15/08

  of synthetic resin · CPC title

• C25D11/243

  using organic dyestuffs · CPC title

• Y10T156/1082

  Partial cutting bonded sandwich [e.g., grooving or incising] · CPC title