Granted Patent B2

US 12,254,370 · App. 18/627,804 · Granted Mar 18, 2025

Inventors: Maxmillian David Michieli (Littleton, CO); James P. Colleran (Centennial, CO); Barry Mosteller (Castle Pines, CO)

Assignee: CPI CARD GROUP-COLORADO, INC.

G06K19/07722

Abstract

Claims (43)

1. A laminated transaction card comprising:

a core layer including polyethylene;

a first support layer including polyethylene terephthalate glycol coupled to a first surface of the core layer by a first adhesive layer;

a second support layer including polyethylene terephthalate glycol coupled to a second surface of the core layer by a second adhesive layer; and

at least one metal layer deposited on one or more of the first support layer or the second support layer;

at least one print layer formed on an outer surface of the first support layer, the at least one metal layer, or both; and

at least one overlaminate layer interconnected to the at least one metal layer.

2. The laminated transaction card of claim 1 , further comprising an integrated circuit chip disposed in the first support layer or the core layer.

3. The laminated transaction card of claim 2 , further comprising an antenna disposed on the core layer or the first support layer and operably connected to the integrated circuit chip.

4. The laminated transaction card of claim 1 , wherein the at least one metal layer includes one or both of:

a first metal layer deposited on the first support layer; or

a second metal layer deposited on the second support layer.

5. The laminated transaction card of claim 4 , wherein the at last one overlaminate layer includes:

a first overlaminate layer interconnected to the first metal layer by a first outer thermosetting adhesive layer, where the first overlaminate layer is at least partially transparent; and

a second overlaminate layer interconnected to the second metal layer by a second outer thermosetting adhesive layer, where the second overlaminate layer is at least partially transparent.

6. The laminated transaction card of claim 1 , wherein the at least one print layer includes one or more of graphics, human-readable characters, or machine readable markings.

7. The laminated transaction card of claim 1 , wherein the at least one overlaminate layer includes polyvinyl chloride or polyethylene terephthalate glycol.

8. The laminated transaction card of claim 1 , wherein one or more of the core layer, the first support layer, or the second support layer include a post-consumer material.

9. The laminated transaction card of claim 1 , wherein the first adhesive layer and the second adhesive layer include an adhesive formulated to bond the polyethylene or the core layer with the polyethylene terephthalate glycol of the first support layer and the second support layer.

10. An inlay for a laminated transaction card comprising:

a core layer including polyethylene;

a first support layer including polyethylene terephthalate glycol adhered to a first surface of the core layer by a first adhesive layer positioned between the first support layer and the first surface of the core layer;

a second support layer including polyethylene terephthalate glycol adhered to a second surface of the core layer by a second adhesive layer positioned between the second support layer and the second surface of the core layer; and

at least one metal layer deposited on an outer surface of one or more of the first support layer or the second support layer.

11. The inlay of claim 10 , further comprising:

an integrated circuit chip disposed in the first support layer or the core layer; and

an antenna positioned on first surface of the core layer or the first support layer.

12. The inlay of claim 10 , wherein the first adhesive layer and the second adhesive layer include ethylene vinyl acetate.

13. The inlay of claim 10 , further comprising at least one of an antenna, a magnetic strip, or an integrated circuit chip.

14. The inlay of claim 10 , wherein the at least one metal layer includes one or more of aluminum, gold, or an ally including one or more of the foregoing.

15. A method of producing a laminated transaction card, the method comprising:

treating a first surface and a second surface of a core layer effective to increase surface energy of the core layer, wherein the core layer includes polyethylene;

positioning a first support layer and a second support layer on opposing sides of the core layer, the first support layer and the second support layer including polyethylene terephthalate glycol,

disposing a first adhesive layer between the first support layer and a first surface of the core layer, and a second adhesive layer between the second support layer and a second surface of the core layer;

bonding the first support layer to the first surface of the core layer and the second support layer to the second surface of the core layer; and

depositing at least one metal layer on one or more of the first support layer or the second support layer.

16. The method of claim 15 , wherein:

the first adhesive layer is positioned between an inner surface of the first support layer and the core layer; and

the at least one metal layer is deposited on an outer surface of the first support layer.

17. The method of claim 15 , wherein bonding the first support layer to the first surface of the core layer and the second support layer to the second surface of the core layer includes activating the first adhesive layer and the second adhesive layer by applying heat and pressure to the first adhesive layer and the second adhesive layer.

18. The method of claim 17 , wherein the heat applied to the first adhesive layer and the second adhesive layer is above an activation temperature of the first adhesive layer and the second adhesive layer and above a glass transition temperature of the first support layer and the second support layer.

19. The method of claim 15 , wherein depositing at least one metal layer on one or more of the first support layer or the second support layer includes vaporizing metal using vacuum deposition.

20. The method of claim 15 , further comprising applying at least one print layer to an outer surface of the at least one metal layer.

Assignments (3)

Continuity (3)

References Cited (39)