Durable card
Cards embodying the invention include a core subassembly whose elements define the functionality of the card and a hard coat subassembly attached to the top and/or bottom sides of the core subassembly to protect the core subassembly from wear and tear and being scratched. The core subassembly may be formed solely of plastic layers or of different combinations of plastic and metal layers and may include all the elements of a smart card enabling contactless RF communication and/or direct contact communication. The hard coat subassembly includes a hard coat layer, which typically includes nanoparticles, and a buffer or primer layer formed so as to be attached between the hard coat layer and the core subassembly for enabling the lasering of the core subassembly without negatively impacting the hard coat layer and/or for imparting color to the card.
1. A method for personalizing transaction cards, the method comprising: forming an internal core layer that includes a laser reactive layer adapted to be personalized by a laser beam, wherein the laser reactive layer is characterized by a tendency to develop heat at or above a predetermined intensity during laser personalization adjacent the points being lasered;
forming an external hard coat layer including nanoparticles selected from the group consisting of silicate nanoparticles, zinc oxide nanoparticles, and silicon dioxide crystalline nanoparticles, said hard coat layer characterized by a tendency to crack when subjected to the predetermined intensity of heat; and
forming at least one buffer layer that is configured to absorb energy and heat imparted to the internal core layer by the laser beam during personalization and prevent the heat generated due to the laser beam from adversely affecting the external hard coat layer, the buffer layer being arranged between the external hard coat layer and the internal core layer; and
personalizing the internal core layer of the transaction card by lasering through the external hard coat layer and the buffer layer before impacting the internal core layer at a temperature that is (i) sufficiently high to cause the laser reactive layer to react and transfer heat to the buffer layer, and (ii) below a cracking temperature of the hard coat layer, to avoid cracking the external hard coat layer.
2. The method as claimed in claim 1 wherein the laser reactive layer is a metal layer.
3. The method as claimed in claim 1 wherein the at least one buffer layer is at least one of the following: (a) polyvinyl dichloride; (b) a plastic material comprising colorants, dyes or pigments; (c) polyvinyl chloride (PVC), polyvinyl acetate (PVAC), amorphous polyethylene terephthalate (APET), or Polyethylene Terephthalate Glycol (PETG).
4. The method of claim 1 , wherein personalizing the internal core layer comprises generating heat at the internal core layer in excess of the predetermined intensity of heat at which said external hard coat layer has a tendency to crack, and absorbing or dissipating with the at least one buffer layer a sufficient amount of heat to prevent cracking of the hard coat layer.
5. The method of claim 1 , wherein the external hard coat layer comprises the nanoparticles dispersed within a carrier comprising a solvent of water based acrylates, vinyls or urethane.