IP Library Granted Patent US 12,217,115
Granted Patent B2
US 12,217,115 · App. 18/630,612 · Granted Feb 4, 2025

Recovered plastic cards

Inventors: Maxmillian D. Michieli (Littleton, CO); James P. Colleran (Centennial, CO); Barry Mosteller (Castle Pines, CO)
Assignee: CPI CARD GROUP—COLORADO, INC.
G06K19/07722B32B7/12B32B27/08B32B27/304B32B27/32B32B37/1207G06K19/07773B32B2250/40B32B2255/10B32B2255/26B32B2307/732B32B2310/14B32B2323/04B32B2327/06B32B2425/00
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,217,115
App. No.
18/630,612
Granted
Feb 4, 2025
Kind
B2
Abstract

An inlay for a laminated transaction card may include a core layer including at least about 50% recycled polyethylene by weight. The inlay may include a first support layer 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 material of the first support layer may include one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate. The inlay may include a second support layer 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. A material of the second support layer may include one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate.

Claims (34)

1. An inlay for a laminated transaction card comprising:

a core layer comprising at least about 50% recycled polyethylene by weight;

a first support layer 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, wherein a material of the first support layer includes one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate; and

a second support layer 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, wherein a material of the second support layer includes one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate.

2. The inlay of claim 1 , further comprising:

an antenna positioned between the first surface of the core layer and the first support layer.

3. The inlay of claim 1 , wherein the first adhesive layer and the second adhesive layer comprise an adhesive formulated to bond to both the recycled polyethylene and the polymer-based support layers.

4. The inlay of claim 1 , wherein the first adhesive layer and the second adhesive layer are ethylene vinyl acetate.

5. The inlay of claim 1 , further comprising a communication element.

6. The inlay of claim 5 , wherein the communication element includes at least one of an antenna, a magnetic strip, and an integrated circuit chip.

7. A laminated card, comprising:

a core layer comprising at least about 70% recycled polyethylene by weight, and having a thickness of at least about 15% of a total thickness of the laminated card;

a polymer-based first support layer interconnected on an inward-facing side thereof to a first side of the core layer by a first thermoplastic adhesive layer, the first support layer having a thickness of at least about 12% of a total thickness of the laminated card, and the first support layer including one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate;

a polymer-based second support layer interconnected on an inward-facing side thereof to a second side of the core layer by a second thermoplastic adhesive layer, the second support layer having a thickness of at least about 12% of a total thickness of the laminated card, and the second support layer including one of polyvinyl chloride, polyethylene terephthalate glycol, or polyethylene terephthalate; and

human-readable account indicia visible from and defined at an outer surface of one of a first side and a second side of the laminated card.

8. A laminated card as recited in claim 7 , the recycled polyethylene of the core layer comprising at least 90% by weight recovered ocean-bound plastic waste.

9. A laminated card as recited in claim 7 , the core layer comprising at least about 90% recycled polyethylene by weight, and having a density of at least about 9 g/cm 3 .

10. A laminated card as recited in claim 7 , the first side and the second side of the core layer having a surface energy of at least about 40 dyne.

11. A laminated card as recited in claim 7 , the core layer, the first support layer, and the second support layer each having corresponding melting point temperatures greater than an activation temperature of the first thermoplastic adhesive layer and an activation temperature of the second thermoplastic adhesive layer.

12. A laminated card as recited in claim 11 , the first support layer and the second support layer each having a Vicat softening temperature of at least about 80° C.

13. A laminated card as recited in claim 11 , the first thermoplastic adhesive layer and the second thermoplastic adhesive layer having corresponding activation temperatures of about 100° C. to about 120° C.

14. A laminated card as recited in claim 7 , the first thermoplastic adhesive layer having an activation temperature of no more than about 130° C. and the second thermoplastic adhesive layer having an activation temperature of no more than about 130° C.

15. A laminated card as recited in claim 14 , the core layer having a Vicat softening temperature of at least about 120° C.

16. A laminated card as recited in claim 7 , wherein the core layer and the first support layer, and the core layer and the second support layer, being interconnected by the first thermoplastic adhesive layer and the second thermoplastic adhesive layer, respectively, by the application of heat and pressure in a lamination process to obtain a temperature of about 100° C. to about 130° C. across the first support layer, the first thermoplastic layer, the core layer, the second thermoplastic adhesive layer and the second support layer, and wherein a pressure of about 0.55 N/mm 2 to about 0.83 N/mm 2 is applied across the first support layer, the first thermoplastic layer, the core layer, the second thermoplastic adhesive layer and the second support layer during the application of heat.

17. A laminated card as recited in claim 7 , the first support layer and the second support layer comprising a same one of or different ones of:

polyvinyl chloride;

polyethylene terephthalate glycol;

polyethylene terephthalate; and

polycarbonate.

18. A laminated card as recited in claim 7 , the first thermoplastic adhesive layer and the second thermoplastic adhesive layer comprising a same one of or different ones of:

ethylene vinyl acetate;

acrylic; and

urethane.

19. A laminated card as recited in claim 7 , the core layer having a thickness of at least about 30% of a total thickness of the laminated card.

Assignments (3)
SECURITY INTEREST Recorded Jul 12, 2024
From: CPI CARD GROUP – COLORADO, INC.; CPI CARD GROUP – MINNESOTA, INC.; CPI CARD GROUP – TENNESSEE, INC.
To: JPMORGAN CHASE BANK, N.A., AS AGENT
Reel/Frame 068310/0406 →
SECURITY INTEREST Recorded Jul 11, 2024
From: CPI CARD GROUP – TENNESSEE, INC.; CPI CARD GROUP – MINNESOTA, INC.; CPI CARD GROUP – COLORADO, INC.
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES COLLATERAL AGENT
Reel/Frame 068292/0703 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 11, 2024
From: MICHIELI, MAXMILLIAN DAVID; COLLERAN, JAMES P.; MOSTELLER, BARRY
To: CPI CARD GROUP - COLORADO, INC.
Reel/Frame 067080/0731 →