U.S. patent application number 10/898078 was filed with the patent office on 2005-03-10 for transaction card.
Invention is credited to Faenza, William J. JR., Lasch, Ellen, Vigiletti, Judy, Webb, Lisa.
Application Number | 20050051633 10/898078 |
Document ID | / |
Family ID | 46278923 |
Filed Date | 2005-03-10 |
United States Patent
Application |
20050051633 |
Kind Code |
A1 |
Lasch, Ellen ; et
al. |
March 10, 2005 |
Transaction card
Abstract
The present invention relates to a process for producing an
opaque, transparent or translucent transaction card having multiple
features, such as a holographic foil, integrated circuit chip,
silver magnetic stripe with text on the magnetic stripe, opacity
gradient, an invisible optically recognizable compound, a
translucent signature field such that the signature on back of the
card is visible from the front of the card and an active thru date
on the front of the card. The invisible optically recognizable
compound is an infrared ink and/or film, which can be detected by a
sensor found in an ATM or card assembly line.
Inventors: |
Lasch, Ellen; (New York
City, NY) ; Webb, Lisa; (Darien, CT) ;
Vigiletti, Judy; (Croton on Hudson, NY) ; Faenza,
William J. JR.; (Andreas, PA) |
Correspondence
Address: |
MCDERMOTT, WILL & EMERY LLP
227 WEST MONROE STREET
CHICAGO
IL
60606-5096
US
|
Family ID: |
46278923 |
Appl. No.: |
10/898078 |
Filed: |
July 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10898078 |
Jul 23, 2004 |
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10394914 |
Mar 21, 2003 |
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10394914 |
Mar 21, 2003 |
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10092681 |
Mar 7, 2002 |
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6764014 |
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10092681 |
Mar 7, 2002 |
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10062106 |
Jan 31, 2002 |
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6749123 |
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10062106 |
Jan 31, 2002 |
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09653837 |
Sep 1, 2000 |
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6581839 |
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10062106 |
Jan 31, 2002 |
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09652899 |
Aug 31, 2000 |
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60153112 |
Sep 7, 1999 |
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60160519 |
Oct 20, 1999 |
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60167405 |
Nov 24, 1999 |
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60171689 |
Dec 21, 1999 |
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Current U.S.
Class: |
235/487 |
Current CPC
Class: |
G06K 19/16 20130101;
G06K 19/02 20130101; G06K 19/08 20130101; B32B 2309/12 20130101;
B42D 25/351 20141001; B32B 2305/28 20130101; G07F 7/0833 20130101;
B42D 25/318 20141001; B42D 25/46 20141001; G07F 7/08 20130101; G06Q
20/00 20130101; B42D 25/369 20141001; B42D 2033/04 20130101; B32B
2425/00 20130101; B42D 25/00 20141001; B32B 2310/0831 20130101;
B42D 25/475 20141001; G06K 7/0013 20130101; G06K 19/077 20130101;
B32B 37/10 20130101; B32B 2309/02 20130101; B42D 25/382 20141001;
B42D 25/47 20141001; G06K 7/10 20130101; G06K 7/084 20130101; G06K
19/0723 20130101; B42D 25/328 20141001; B42D 2033/06 20130101; G03H
2250/12 20130101; B42D 25/455 20141001; G06K 13/08 20130101; G06K
19/07 20130101; G06Q 20/14 20130101; B32B 38/145 20130101; B32B
2305/22 20130101; G06K 7/0008 20130101 |
Class at
Publication: |
235/487 |
International
Class: |
G06K 019/00 |
Claims
1-47. (cancelled)
48. A financial transaction card that is transparent or translucent
to human viewing yet detectable by automated card processing
equipment comprising: a substantially planar material sheet having
upper and lower surfaces bounded by a continuous peripheral edge;
said material sheet having one or more areas that are at least
minimally transparent or translucent to human viewing; and a filter
associated with at least one of said one or more areas, said filter
providing sufficient opacity to light that is used by card sensors
in said automated card processing equipment to render said card
detectable by said equipment.
49. A financial transaction card in accordance with claim 48
wherein said card transmits human visible light with at least about
15% transmittance.
50. A financial transaction card in accordance with claim 48
wherein said automated card processing equipment includes card
embossing/encoding machines having source/detector pairs operating
in a light wavelength range of about 830-1100 nm, and wherein said
filter has an opacity relative to one or more specific wavelengths
within said range of not substantially less than about 1.0.
51. A financial transaction card in accordance with claim 50
wherein said one or more specific wavelengths include about 920 nm
and about 950 nm.
52. A financial transaction card in accordance with claim 48
wherein said automated card processing equipment includes card
readers having source/detector pairs operating in a light
wavelength range of about 750-1200 nm, and wherein said filter has
an opacity relative to one or more specific wavelengths within said
range of not substantially less than about 1.0.
53. A financial transaction card in accordance with claim 52
wherein said one or more specific wavelengths include about 890 nm
and about 950 nm.
54. A financial transaction card in accordance with claim 48
wherein said automated card processing equipment includes card
embossing/encoding machines having source/detector pairs operating
in a light wavelength range of about 830-1100 nm, and card readers
having source/detector pairs operating in a light wavelength range
of about 750-1200 nm, and wherein said filter has an opacity
relative to one or more specific wavelengths within said 750-1200
nm range of not substantially less than about 1.0.
55. A financial transaction card in accordance with claim 54
wherein said one or more specific wavelengths include about 890 nm,
about 920 nm, and about 950 nm.
56. A financial transaction card in accordance with claim 48
wherein said filter is a light absorbing material, a light
reflecting material, a light deflecting material, or a combination
of two or more such materials.
57. A financial transaction card in accordance with claim 48
wherein said filter is formed as a filter coating, film or
deposition applied or secured to said material sheet.
58. A financial transaction card in accordance with claim 57
wherein said filter is a clear, light absorbing material providing
the requisite light filtering properties.
59. A financial transaction card in accordance with claim 57
wherein said filter is formed from a light absorbing dye.
60. A financial transaction card in accordance with claim 57
wherein said filter is formed from a light reflecting material.
61. A financial transaction card in accordance with claim 57
wherein said filter is formed from a light scattering material.
62. A financial transaction card in accordance with claim 48
wherein said filter is formed from a light filtering material
disbursed through all or a portion of said material sheet.
63. A method for manufacturing a financial transaction card that is
transparent or translucent to human viewing yet detectable by
automated card processing equipment, comprising the steps of:
forming a substantially planar material sheet having upper and
lower surfaces bounded by a continuous peripheral edge; said
material sheet being formed with one or more areas that are least
minimally transparent or translucent to human viewing; and
associating a filter with at least a portion of said material
sheet, said filter providing sufficient opacity to light that is
used by card sensors in said automated card processing equipment to
render said card detectable by said equipment.
64. A method in accordance with claim 63 wherein said card
transmits human visible light with at least about 15%
transmittance.
65. A method in accordance with claim 63 wherein said automated
card processing equipment includes card embossing/encoding machines
having source/detector pairs operating in a light wavelength range
of about 830-1100 nm, and wherein said filter is constructed to
have an opacity relative to one or more specific wavelengths within
said range of not substantially less than about 1.0.
66. A method in accordance with claim 65 wherein said one or more
specific wavelengths include about 920 nm and about 950 nm.
67. A method in accordance with claim 63 wherein said automated
card processing equipment includes card readers having
source/detector pairs operating in a light wavelength range of
about 750-1200 nm, and wherein said filter is constructed to have
an opacity relative to one or more specific wavelengths within said
range of not substantially less than about 1.0.
68. A method in accordance with claim 67 wherein said one or more
specific wavelengths include about 890 nm and about 950 nm.
69. A method in accordance with claim 63 wherein said automated
card processing equipment includes card embossing/encoding machines
having source/detector pairs operating in a light wavelength range
of about 830-1100 nm, and card readers having source/detector pairs
operating in a light wavelength range of about 750-1200 nm, and
wherein said filter is constructed to have an opacity relative to
one or more specific wavelengths within said 750-1200 nm range of
not substantially less than about 1.0.
70. A method in accordance with claim 69 wherein said one or more
specific wavelengths include about 890 nm, about 920 nm, and about
950 nm.
71. A method in accordance with claim 63 wherein said filter is a
light absorbing material, a light reflecting material, a light
deflecting material, or a combination of two or more such
materials.
72. A method in accordance with claim 63 wherein said filter is
formed as a filter coating, film or deposition applied or secured
to said material sheet.
73. A method in accordance with claim 72 wherein said filter is
formed from a clear light absorbing material providing the
requisite light filtering properties.
74. A method in accordance with claim 72 wherein said filter is
formed from a light absorbing dye.
75. A method in accordance with claim 72 wherein said filter formed
from a light reflecting material.
76. A method in accordance with claim 72 wherein said filter formed
from a light scattering material.
77. A method in accordance with claim 63 said filter is formed from
a light filtering material disbursed through all or a portion of
said material sheet.
78. A financial transaction card that is transparent or translucent
to human viewing yet detectable by automated card processing
equipment, comprising: a sheet of material having one or more areas
that are at least minimally transparent or translucent to human
viewing; and means associated with at least one of said areas for
rendering said card detectable by source/detector pairs in said
automated processing equipment.
79. A financial transaction card in accordance with claim 78
wherein said means is a filter applied to said material sheet as a
liquid coating.
80. A financial transaction card in accordance with claim 79
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material at a dye-to-coating weight
ratio of up to about 20%.
81. A financial transaction card in accordance with claim 79
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material at a dye-to-coating weight
ratio of between about 0.2-5.0%.
82. A financial transaction card in accordance with claim 79
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material at a dye-to-coating weight
ratio of between about 0.5-3.5%.
83. A financial transaction card in accordance with claim 79
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material at a weight ratio of about
1.0-2.5 %.
84. A financial transaction card in accordance with claim 79
wherein said liquid coating comprises a plastic resin-based coating
material.
85. A financial transaction card in accordance with claim 79
wherein said liquid coating is applied to said material sheet by
screen printing.
86. A financial transaction card in accordance with claim 85
wherein said screen printing is performed using a screen mesh size
of between about 90-390 mesh.
87. A financial transaction card in accordance with claim 85
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material and said screen printing is
performed using a screen mesh size of about 195 mesh.
88. A financial transaction card in accordance with claim 85
wherein said filter is made from a light absorbing dye material
dissolved in a liquid coating material and said screen printing is
performed using a screen mesh size of about 305 mesh.
89. A financial transaction card in accordance with claim 80
wherein said liquid coating material is a plastic resin-based
coating.
90. A financial transaction card in accordance with claim 80
wherein a colorant is added to said filter to provide a desired
color or tint.
91. A financial transaction card in accordance with claim 90
wherein said dye is a dye material that produces a yellow tint and
wherein said colorant is a violet colorant material that combines
with said yellow tint of said dye material to provide a neutral
gray tint in said card.
92. A financial transaction card in accordance with claim 80
wherein between about 2-4 layers of said dye material and said
liquid coating material are applied to said material sheet.
93. A financial transaction card in accordance with claim 80
wherein said card has an opacity of at least approximately 1.0
relative to one or more selected light wavelengths corresponding to
the output of light sources used in said automated card processing
equipment.
94. A financial transaction card in accordance with claim 93
wherein said card has an opacity of at least approximately 1.0
relative to light wavelengths of about 890 nm and about 950 nm.
95. A financial transaction card in accordance with claim 93
wherein said card has an opacity of at least approximately 1.0
relative to light wavelengths of about 920 nm and about 950 nm.
96. A financial transaction card in accordance with claim 90
wherein said colorant is a dye colorant.
97. A financial transaction card in accordance with claim 90
wherein said colorant is a fluorescent material.
98. A financial transaction card in accordance with claim 90
wherein said colorant is a light scattering material.
99. A financial transaction card in accordance with claim 90
wherein said colorant includes a fluorescent material and a light
scattering material.
100. A financial transaction card in accordance with claim 79
wherein said filter includes a fluorescent material.
101. A financial transaction card in accordance with claim 79
wherein said filter includes a light scattering material.
102. A financial transaction card in accordance with claim 79
wherein said filter includes a fluorescent material and a light
scattering material.
103. A financial transaction card in accordance with claim 79
wherein said filter includes an Ultraviolet light absorber.
104. A financial transaction card in accordance with claim 79
wherein said filter is made from an organic solvent-soluble, near
Infrared absorption dye and an Ultraviolet light absorbing material
dissolved in a plastic resin-based coating material.
105. A financial transaction card in accordance with claim 79
wherein said coating is made from a vinyl resin-based coating
material that includes (by weight) about 20-25% vinyl resins, about
35-40% aromatic petroleum distillates, about 5-10% cyclohexanone,
about 5-10% diacetone alcohol, about 5-10% gamma butyrolactone,
less than about 5% napthalene, and about 2% aliphatic petroleum
distillates, and wherein said coating is further made from a
thinner comprising all of the components of said coating material
at the same ratios, with the exception of said vinyl resins which
are not present in said thinner.
106. A financial transaction card in accordance with claim 105
wherein said filter is made from one or more layers comprising a
mixture of a first organic solvent-soluble, near Infrared
absorption dye, a second organic solvent-soluble, near Infrared
absorption dye, said second dye having more Ultraviolet light
and/or heat stability than said first dye, an organic
solvent-soluble red colorant, an organic solvent-soluble blue
colorant, said thinner and said vinyl resin-based coating
material.
107. A financial transaction card in accordance with claim 106
wherein the respective proportions of said first dye, said second
dye, said red colorant, said blue colorant, said thinner, and said
vinyl resin-based coating material in said mixture are about
22:3:0.25:0.35:110:990 by weight, and wherein two filter layers of
said mixture are used to produce a card having an opacity of
approximately 0.4 at a wavelength of about 550 nm, approximately
1.3 at a wavelength of about 890 nm, and approximately 1.7 at a
wavelength of about 950 nm.
108. A financial transaction card in accordance with claim 106
wherein the respective proportions of said first dye, said second
dye, said red colorant, said blue colorant, said thinner, and said
vinyl resin-based coating material in said mixture are about
22:3:0.25:0.35:110:990 by weight, and wherein three filter layers
of said mixture are used to produce a card having an opacity of
approximately 0.6 at a wavelength of about 550 nm, approximately
1.5 at a wavelength of about 890 nm and approximately 1.9 at a
wavelength of about 950 nm.
109. A financial transaction card in accordance with claim 106
wherein the respective proportions of said first dye, said second
dye, said red colorant, said blue colorant, said thinner, and said
vinyl resin-based coating material in said mixture are about
22:3:0.25:0.35:110:990 by weight, and wherein four filter layers of
said mixture are used to produce a card having an opacity of
approximately 0.6 at a wavelength of about 550 nm, approximately
2.0 at a wavelength of about 890 nm and approximately 2.5 at a
wavelength of about 950 nm.
110. A financial transaction card in accordance with claim 105
wherein said filter is made from one or more layers comprising a
mixture of an organic solvent-soluble, near Infrared absorption
dye, an organic solvent-soluble Ultraviolet (UV) light absorber, an
organic solvent-soluble fluorescent blue colorant, an organic
solvent-soluble fluorescent red colorant, said thinner and said
vinyl resin-based coating material.
111. A financial transaction card in accordance with claim 110
wherein the respective proportions of said dye, said UV absorber,
said blue colorant, said red colorant, said thinner, and said vinyl
resin-based coating material in said mixture are about
13:4.33:21.66:21.66:130:633 by weight, and wherein three filter
layers of said mixture are used to produce a card having an opacity
of approximately 0.2 at a wavelength of about 550 nm and
approximately 1.0 at a wavelength of about 950 nm.
112. A financial transaction card in accordance with claim 105
wherein said filter is made from one or more layers comprising a
mixture of an organic solvent-soluble, near Infrared absorption
dye, an organic solvent-soluble Ultraviolet light (UV) absorber,
and said vinyl resin-based coating material.
113. A financial transaction card in accordance with claim 112
wherein the respective proportions of said dye, said UV absorber,
and said vinyl resin-based coating material in said mixture are
about 15:4.5:980.5 by weight, and wherein one filter layer of said
mixture is used to produce a card having an opacity of
approximately 0.2 at a wavelength of about 550 nm and approximately
1.2 at a wavelength of about 950 nm.
114. A financial transaction card in accordance with claim 105
wherein said filter is disposed on one side of said material sheet
and a light scattering film is disposed on the other side of said
material sheet.
115. A financial transaction card in accordance with claim 114
wherein said filter is made from one or more layers comprising a
first mixture of an organic solvent-soluble, near Infrared
absorption dye, an organic solvent-soluble Ultraviolet (UV) light
absorber, an organic solvent-soluble fluorescent blue colorant, an
organic solvent-soluble fluorescent red colorant, said thinner and
said vinyl resin-based coating material, and wherein said light
scattering film is made from one or more layers comprising a second
mixture of a translucent light scattering material, an organic
solvent-soluble fluorescent whitening agent and said vinyl
resin-based coating material.
116. A financial transaction card in accordance with claim 115
wherein the respective proportions of said dye, said UV absorber,
said fluorescent blue colorant, said fluorescent red colorant, said
thinner, and said vinyl resin-based coating material in said first
mixture are about 13:4.33:65:21.66:130:633 by weight, wherein the
respective proportions of said light scattering material, said
fluorescent whitening agent and said vinyl resin-based coating
material in said second mixture are about 90:2.5:907.5, wherein one
filter layer of said first mixture and said light scattering film
coated with said second mixture are used to produce a card having
an opacity of approximately 0.8 at a wavelength of about 550 nm and
approximately 1.5 at a wavelength of about 950 nm.
117. A financial transaction card in accordance with claim 79
wherein said filter is made from an organic solvent-soluble, near
Infrared absorption dye, an organic solvent-soluble Ultraviolet
light absorbing material, and one or more organic solvent-soluble
colorants dissolved in a vinyl resin-based coating.
118. The financial transaction card of claim 79 wherein said filter
is made from an organic solvent-soluble, near Infrared absorption
dye, an organic solvent-soluble Ultraviolet light absorbing
material, and one or more organic solvent-soluble fluorescent
materials dissolved in one or more vinyl resin-based coatings.
119. The financial transaction card of claim 79 wherein said filter
is made from an organic solvent-soluble, near Infrared absorption
dye, an organic solvent-soluble Ultraviolet light absorbing
material, and one or more light scattering materials dissolved in
one or more vinyl resin-based coatings.
120. The financial transaction card of claim 79 wherein said card
transmits human visible light with at least about 15%
transmittance.
121. A financial transaction card that is transparent or
translucent to human viewing yet detectable by automated card
processing equipment, comprising: a pair of substantially planar
material sheets each having opposing first surfaces and
non-opposing second surfaces, said surfaces being bounded by a
continuous peripheral edge; said material sheets being at least
minimally transparent or translucent to human viewing; a light
filtering coating formed on one or both of said first surfaces;
printed graphics formed over said second surfaces; clear protective
overlay sheets formed over said printed graphics; and said card
providing sufficient opacity to light that is detectable by sensors
in said automated card processing equipment to render said card
detectable by said equipment.
122. The financial transaction card of claim 121 wherein there is a
light filtering coating formed one each of said first surfaces.
123. The financial transaction card of claim 121 further including
a light filtering coating formed on one or both of said second
surfaces.
124. The financial transaction card of claim 123 wherein there is a
light filtering coating formed on each of said second surfaces.
125. The financial transaction card of claim 121 wherein said light
filtering coating is a light absorbing coating.
126. The financial transaction card of claim 122 wherein said light
filtering coatings are light absorbing coatings.
127. The financial transaction card of claim 123 wherein said light
filtering coating on one or both of said first surfaces is a light
absorbing coating and said light filtering coating on one or both
of said second surfaces is a light scattering coating.
128. The financial transaction card of claim 124 wherein said light
filtering coating on one or both of said first surfaces is a light
absorbing coating and said light filtering coatings on said second
surfaces are light scattering coatings.
129. The financial transaction card of claim 125 wherein said light
absorbing coating includes a light absorbing dye.
130. The financial transaction card of claim 129 wherein said light
absorbing coating includes a colorant.
131. The financial transaction card of claim 130 wherein said light
absorbing coating includes a light scattering material.
132. The financial transaction card of claim 128 wherein one of
said light scattering coatings comprises a pearlescent ink material
and the other of said light scattering coatings comprises a
pearlescent pigment material.
133. The financial transaction card of claim 132 wherein one of
said light scattering coatings comprises a silica powder.
134. The financial transaction card of claim 124 wherein: (1) there
is a light filtering coating formed on one of said first surfaces
that is made from a filtering mixture that includes an organic
solvent-soluble, near Infrared absorption dye, an organic
solvent-soluble blue colorant, an organic solvent-soluble red
colorant, an organic solvent-soluble Ultraviolet (UV) light
absorber, a BHT preservative, a light scattering ceramic sphere
material, a solvent-based thinner and a vinyl resin-based coating
material, said vinyl resin-based coating material including (by
weight) about 20-25% vinyl resins, about 35-40% aromatic petroleum
distillates, about 5-10% cyclohexanone, about 5-10% diacetone
alcohol, about 5-10% gamma butyrolactone, less than about 5%
napthalene, and about 2% aliphatic petroleum distillates, and said
thinner comprising all of the components of said coating material
at the same ratios, with the exception of said vinyl resins which
are not present in said thinner, said dye, said blue colorant, said
red colorant, said UV absorber, said preservative, said ceramic
sphere material, said thinner and said vinyl resin-based coating
material being present in said filtering mixture at respective
proportions of about 69:7.2:6:30:30:780:300:4777.8 by weight; (2)
said light filtering coating formed on one of said second surfaces
is made from a pearlescent ink; (3) said light filtering coating
formed on the other of said second surfaces is made from a light
scattering mixture that includes an organic solvent-soluble
pearlescent pigment, an organic solvent-soluble fluorescent
whitening agent, a powdered silica material, and a vinyl
resin-based coating material, said vinyl resin-based coating
material including (by weight) about 20-25% vinyl resins, about
35-40% aromatic petroleum distillates, about 5-10% cyclohexanone,
about 5-10% diacetone alcohol, about 5-10% gamma butyrolactone,
less than about 5% napthalene, and about 2% aliphatic petroleum
distillates, said pearlescent pigment, said fluorescent whitening
agent, said powdered silica material, and said vinyl resin-based
coating material being present in said light scattering mixture at
respective proportions of about 101:25:5:869 by weight; and (4)
said card has an opacity of approximately 0.7 over a wavelength
range of about 400-750 nm, approximately 1.5 at a wavelength of
about 890 nm, and approximately 1.6 at a wavelength of about 950
mm.
135. The financial transaction card of claim 122 wherein: (1) there
is a light filtering coating formed on each of said first surfaces
that is made from a filtering mixture that includes an organic
solvent-soluble, near Infrared absorption dye, an organic
solvent-soluble Ultraviolet (UV) light absorber, a BHT
preservative, a light scattering ceramic sphere material, a
solvent-based thinner and a vinyl resin-based coating material,
said vinyl resin-based coating material including (by weight) about
20-25% vinyl resins, about 35-40% aromatic petroleum distillates,
about 5-10% cyclohexanone, about 5-10% diacetone alcohol, about
5-10% gamma butyrolactone, less than about 5% napthalene, and about
2% aliphatic petroleum distillates, and said thinner comprising all
of the components of said coating material at the same ratios, with
the exception of said vinyl resins which are not present in said
thinner, said dye, said UV absorber, said preservative, said
ceramic sphere material, said thinner and said vinyl resin-based
coating material being present in said filtering mixture at
respective proportions of about 15:5:5:130:50:795 by weight; and
(2) said card has an opacity of approximately 0.2 over a wavelength
range of about 400-750 nm, approximately 1.4 at a wavelength of
about 890 nm, and approximately 1.9 at a wavelength of about 950
nm.
136. The financial transaction card of claim 122 wherein: (1) there
is a light filtering coating formed on each of said first surfaces
that is made from a filtering mixture that includes an organic
solvent-soluble, near Infrared absorption dye, an organic
solvent-soluble blue colorant, an organic solvent soluble red
colorant, an organic solvent-soluble Ultraviolet (UV) light
absorber, a BHT preservative, a light scattering ceramic sphere
material, a solvent-based thinner and a vinyl resin-based coating
material, said vinyl resin-based coating material including (by
weight) about 20-25% vinyl resins, about 35-40% aromatic petroleum
distillates, about 5-10% cyclohexanone, about 5-10% diacetone
alcohol, about 5-10% gamma butyrolactone, less than about 5%
napthalene, and about 2% aliphatic petroleum distillates, and said
thinner comprising all of the components of said coating material
at the same ratios, with the exception of said vinyl resins which
are not present in said thinner, said dye, said blue colorant, said
red colorant, said UV absorber, said preservative, said ceramic
sphere material, said thinner and said vinyl resin-based coating
material being present in said filtering mixture at respective
proportions of about 12:3.75:2.75:5:5:130:50:791.5 by weight; and
(2) said card has an opacity of approximately 0.5 over a wavelength
range of about 400-750 nm, approximately 1.1 at a wavelength of
about 890 nm, and approximately 1.6 at a wavelength of about 950
nm.
137. The financial transaction card of claim 122 wherein: (1) there
is a light filtering coating formed on each of said first surfaces
that is made from a filtering mixture that includes an organic
solvent-soluble, near Infrared absorption dye, a solvent-based
liquid blue colorant, an organic solvent-soluble blue colorant, an
organic solvent-soluble red colorant, an organic solvent-soluble
Ultraviolet (UV) light absorber, a BHT preservative, a light
scattering ceramic sphere material, a solvent-based thinner and a
vinyl resin-based coating material, said vinyl resin-based coating
material including (by weight) about 20-25% vinyl resins, about
35-40% aromatic petroleum distillates, about 5-10% cyclohexanone,
about 5-10% diacetone alcohol, about 5-10% gamma butyrolactone,
less than about 5% napthalene, and about 2% aliphatic petroleum
distillates, and said thinner comprising all of the components of
said coating material at the same ratios, with the exception of
said vinyl resins which are not present in said thinner, said dye,
said liquid blue colorant, said blue colorant, said red colorant,
said UV absorber, said preservative, said ceramic sphere material,
said thinner and said vinyl resin-based coating material being
present in said filtering mixture at respective proportions of
about 12:20:3.75:2.75:5:5:130:50:771- .5 by weight; and (2) said
card has an opacity of approximately 0.6 over a wavelength range of
about 400-750 nm, approximately 1.3 at a wavelength of about 890
nm, and approximately 1.8 at a wavelength of about 950 nm.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part
application of U.S. patent application Ser. No. ______, filed Jan.
31, 2001, which is a continuation-in-part application of U.S.
patent application Ser. No. 09/653,837, filed Sep. 1, 2000 and
further claims the benefit of U.S. Provisional Application No.
60/153,112, filed Sep. 7, 1999; U.S. Provisional Application No.
60/160,519, filed Oct. 20, 1999; U.S. Provisional Application No.
60/167,405, filed Nov. 24, 1999; U.S. Provisional Patent
Application No. 60/171,689, filed Dec. 21, 1999 and U.S. patent
application Ser. No. 09/652,899, entitled "Methods And Apparatus
For Conducting Electronic Transactions" filed Aug. 31, 2000.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to a transaction
card, and more particularly, to the fabrication and use of an
optically recognizable transparent or translucent transaction card
that may contain a hologram, magnetic stripe or integrated circuit
as well as other transaction card constituents.
BACKGROUND OF THE INVENTION
[0003] The proliferation of transaction cards, which allow the
cardholder to pay with credit rather than cash, started in the
United States in the early 1950s. Initial transaction cards were
typically restricted to select restaurants and hotels and were
often limited to an exclusive class of individuals. Since the
introduction of plastic credit cards, use of transaction cards have
rapidly proliferated from the United States, to Europe, and then to
the rest of the world. Transaction cards are not only information
carriers, but-also typically allow a consumer to pay for goods and
services without the need to constantly possess cash, or if a
consumer needs cash, transaction cards allow access to funds
through an automatic teller machine (ATM). Transaction cards also
reduce the exposure to the risk of cash loss through theft and
reduce the need for currency exchanges when traveling to various
foreign countries. Due to the advantages of transaction cards,
hundreds of millions of cards are now produced and issued annually,
thereby resulting in need for companies to differentiate their
cards from competitor's cards.
[0004] Initially, the transaction cards often included the issuer's
name, the cardholder's name, the card number, and the expiration
date embossed onto the card. The cards also usually included a
signature field on the back of the card for the cardholder to
provide a signature to protect against forgery and tempering. Thus,
the initial cards merely served as devices to provide data to
merchants and the only security associated with the card was the
comparison of the cardholder's signature on the card to the
cardholder's signature on a receipt along with the embossed
cardholder name on the card. However, many merchants often forget
to verify the signature on the receipt with the signature on the
card.
[0005] Due to the popularity of transaction cards, numerous
companies, banks, airlines, trade groups, sporting teams, clubs and
other organizations have developed their own transaction cards. As
such, many companies continually attempt to differentiate their
transaction cards and increase market share not only by offering
more attractive financing rates and low initiation fees, but also
by offering unique, aesthetically pleasing features on the
transaction cards. As such, many transaction cards included not
only demographic and account information, but the transaction cards
also include graphic images, designs, photographs and security
features. A recent security feature is the incorporation of a
diffraction grating, or holographic image, into the transaction
card which appears to be three dimensional and which substantially
restricts the ability to fraudulently copy or reproduce transaction
cards because of the need for extremely complex systems and
apparatus for producing holograms. A hologram is produced by
interfering two or more beams of light, namely an object beam and
reference beam, onto a photo emulsion to thereby record the
interference pattern produced by the interfering beams of light.
The object beam is a coherent beam reflected from, or transmitted
through, the object to be recorded, such as a company logo, globe,
character or animal. The reference beam is usually a coherent,
collimated light beam with a spherical wave front. After recording
the interference pattern, a similar wavelength reference beam is
used to produce a holographic image by reconstructing the image
from the interference pattern.
[0006] However, in typical situations, a similar laser beam is not
available to reconstruct the image from the interference pattern on
the card. As such, the hologram should be able to be viewed with
ordinary, white light. Thus, when a hologram is recorded onto a
transaction card, the image to be recorded is placed near the
surface of the substrate to allow the resulting hologram to be
visible in ordinary, white light. These holograms are known as
reflective surface holograms or rainbow holograms. A reflective
hologram can be mass-produced on metallic foil and subsequently
stamped onto transaction cards. Moreover, the incorporation of
holograms onto transaction cards provides a more reliable method of
determining the authenticity of the transaction card in ordinary
white light, namely by observing if the hologram has the illusion
of depth and changing colors.
[0007] Administrative and security issues, such as charges,
credits, merchant settlement, fraud, reimbursements, etc., have
increased due to the increasing use of transaction cards. Thus, the
transaction card industry started to develop more sophisticated
transaction cards which allowed the electronic reading,
transmission, and authorization of transaction card data for a
variety of industries. For example, magnetic stripe cards, optical
cards, smart cards, calling cards, and supersmart cards have been
developed to meet the market demand for expanded features,
functionality, and security. In addition to the visual data, the
incorporation of a magnetic stripe on the back of a transaction
card allows digitized data to be stored in machine readable form.
As such, magnetic stripe reader are used in conjunction with
magnetic stripe cards to communicate purchase data received from a
cash register device on-line to a host computer along with the
transmission of data stored in the magnetic stripe, such as account
information and expiration date.
[0008] Due to the susceptibility of the magnetic stripe to
tampering, the lack of confidentiality of the information within
the magnetic stripe and the problems associated with the
transmission of data to a host computer, integrated circuits were
developed which could be incorporated into transaction cards. These
integrated circuit (IC) cards, known as smart cards, proved to be
very reliable in a variety of industries due to their advanced
security and flexibility for future applications.
[0009] As magnetic stripe cards and smart cards developed, the
market demanded international standards for the cards. The card's
physical dimensions, features and embossing area were standardized
under the International Standards Organization ("ISO"), ISO 7810
and ISO 7811. The issuer's identification, the location of
particular compounds, coding requirements, and recording techniques
were standardized in ISO 7812 and ISO 7813, while chip card
standards were established in ISO 7813. For example, ISO 7811
defines the standards for the magnetic stripe which is a 0.5 inch
stripe located either in the front or rear surface of the card
which is divided into three longitudinal parallel tracks. The first
and second tracks hold read-only information with room for 79 alpha
numeric characters and 40 numeric characters, respectively. The
third track is reserved for financial transactions and includes
enciphered versions of the user's personal identification number,
country code, currency units, amount authorized per cycle,
subsidiary accounts, and restrictions. More information regarding
the features and specifications of transaction cards can be found
in, for example, Smart Cards by Jose Luis Zoreda and Jose Manuel
Oton, 1994; Smart Card Handbook by W. Rankl and W. Effing, 1997,
and the various ISO standards for transaction cards available from
ANSI (American National Standards Institute), 11 West 42nd Street,
New York, N.Y. 10036, the entire contents of all of these
publications are herein incorporated by reference.
[0010] The incorporation of machine-readable components onto
transactions cards encouraged the proliferation of devices to
simplify transactions by automatically reading from and/or writing
onto transaction cards. Such devices include, for example, bar code
scanners, magnetic stripe readers, point of sale terminals (POS),
automated teller machines (ATM) and card-key devices. With respect
to ATMs, the total number of ATM devices shipped in 1999 is 179,274
(based on Nilson Reports data) including the ATMs shipped by the
top ATM manufacturers, namely NCR (138-18 231st Street, Laurelton,
N.Y. 11413), Diebold (5995 Mayfair, North Canton, Ohio 44720-8077),
Fujitsu (11085 N. Torrey Pines Road, La Jolla, Calif. 92037), Omron
(Japan), OKI (Japan) and Triton.
[0011] Many of the card acceptance devices require that the
transaction card be inserted into the device such that the device
can appropriately align its reading head with the relevant
component of the transaction card. Particularly, many ATMs require
that a transaction card be substantially inserted into a slot in
the ATM. After insertion of the card into the slot, the ATM may
have an additional mechanical device for further retracting the
transaction card into the ATM slot. To activate the ATM, the ATM
typically includes a sensor, such as a phototransistor and a light
emitting diode (LED), which emits light onto a card surface and the
phototransistor receives light from the LED. A card blocks the
infrared radiation from the phototransistor, therefore indicating
that a card has been detected. A typical LED in an ATM is an IRED
(infrared emitting diode) source having a wavelength in the range
of about 820-920 nm or 900-1000 nm (see FIG. 5), which is not
present in ambient light at the levels needed by a phototransistor
sensor. The spectral sensitivity curve of the typical
phototransistor is in the range of about 400 nm-1100 nm (see FIG.
6). However, the visible spectrum is about 400 nm-700 nm, and the
spectral sensitivity of the phototransistor is about 60% at 950 nm
and 90% at 840 nm. Thus, visible light is not part of the
analog-to-digital algorithm. Moreover, ISO 7810, clause 8.10
requires that all machine readable cards have an optical
transmission density from 450 nm-950 nm, greater than 1.3 (less
than 5% transmission) and from 950 nm-1000 nm, greater than 1.1
(less than 7.9% transmission).
[0012] For the card to be detected by the ATM, the light is
typically blocked by the card body. Moreover, the amount of light
necessary to be blocked by a card is related to the voltage data
received from the analog to digital conversion. The voltage range
of the sensor is typically in a range of about 1.5V to 4.5V. When a
card is inserted into a sensor, the voltage drops to less than 1.5V
indicating the presence of a card in the transport system. After
the card is detected by the phototransistor, the magnetic strip
reader scans the magnetic stripe and acquires the information
recorded on the magnetic stripe. A manufacturer of the LED sensor
device in an ATM is, for example, Omron and Sankyo-Ski of Japan,
4800 Great America Parkway, Suite 201, Santa Clara, Calif.
95054.
[0013] As previously mentioned, transaction cards and readers
typically follow various ISO standards which specifically set forth
the location of card data and compounds. However, because numerous
companies produce different versions of ATMs, the location of the
sensor within the ATM is not subject to standardization
requirements. In the past, the varying locations of the sensor
within the ATM did not affect the ability of the ATM to sense the
transaction card because the transaction card included a
substantially opaque surface, such that any portion of the opaque
transaction card could interrupt the IRED emission and activate the
insert phototransistor. However, more recently, to provide a unique
image, and to meet consumer demand, companies have attempted to
develop transparent or translucent transaction cards. The use of a
transparent card would often not activate the insert
phototransistor because the IRED emission would not sufficiently
reflect off of a transparent surface, so the radiation would simply
travel through the card and become detected by the phototransistor.
The machine, therefore, could not detect the presence of the card,
and often jammed the equipment.
[0014] In an attempt to solve this problem, companies have printed
opaque areas onto transparent cards in an effort to provide an
opaque area to activate the input sensors on ATMs. However, due to
the aforementioned variations in the location of the sensor in many
ATMs, the use of limited opaque areas on a transparent card did not
allow the card to activate the sensor in a sufficient number of
ATMs. Alternatively, companies attempted to incorporate a lens onto
a transaction card in an effort to redirect the LED light. However,
during the card manufacture process, which often involves
substantial pressure and heat, the lensing surface would be
disrupted or destroyed. As such, a need exists for a transparent or
translucent transaction card which is capable of activating an
input sensor, wherein the input sensor may interface the card in a
variety of locations.
[0015] Furthermore, during the card fabrication process, the cards
must be detected on the assembly line in order to accurately count
the number of cards produced during a predetermined time interval.
To count the cards, typical card fabrication assembly lines include
counters with LED sensors, similar to the ATM sensors, which count
the cards based upon the reflection of the LED light beam off of
the opaque card surface. The production of transparent transaction
cards suffers from similar limitations as ATM devices in that the
LED beam does not reflect or is not sufficiently absorbed from a
transparent surface. Thus, a transparent card is needed that can be
produced on existing assembly lines. Similar problems exist when
cards are punched to final dimensions.
[0016] Although existing systems may allow for the identification
and detection of articles, most contain a number of drawbacks. For
example, identification features based on UV, visible light
detection, etc. are sometimes difficult to view, often require
certain lighting requirements and typically depend on the distance
between the article and the detection device. Additionally, the use
of certain types of plastic, paper or other material which contain
the identification mark may be limited by the particular
identification device. For example, opaque materials typically
deactivate the phototransistors in ATM's by blocking light in both
the visible (near IR) and far IR light regions. Furthermore, the
incorporation of a detection or authentication feature into a card
product requires a separate material or process step during the
card fabrication process. The incorporation of a new material or
process step often requires expensive modifications to current
equipment or new equipment and often extends the time for
fabricating the card product.
BRIEF SUMMARY OF THE INVENTION
[0017] The present invention relates to a process for producing a
transparent or translucent transaction card having any one or more
features, such as a holographic foil, integrated circuit chip,
silver magnetic stripe with text on the magnetic stripe, opacity
gradient, an optically recognizable ink or film contained within
the construction of the card, a translucent signature field such
that the signature on back of the card is visible from the front of
the card and an "active thru" date on the front of the card. The
card is optically recognizable due to an invisible or transparent
infrared ink or film which is distributed over the card's surface,
thereby allowing the card to block (absorb, refract, diffuse and/or
reflect) infrared light and transmit all other light. Particularly,
when the transaction card is inserted into an ATM device, the light
beam from the IRED is blocked by the infrared ink or film, thereby
deactivating the phototransistor. Moreover, during the manufacturer
of transaction cards, the optically recognizable card allows an
IRED light beam from a personalization device, inspection unit or
counter device to count the number of transaction cards produced in
an assembly line.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0018] A more complete understanding of the present invention may
be derived by referring to the detailed description and claims when
considered in connection with the following illustrative figures,
which may not be to scale. In the following figures, like reference
numbers or steps refer to similar compounds throughout the
figures.
[0019] FIG. 1 is a front view of an exemplary transaction card in
accordance with an exemplary embodiment of the present
invention;
[0020] FIG. 2 is a back view of an exemplary transaction card in
accordance with an exemplary embodiment of the present
invention;
[0021] FIG. 3 is a flow diagram of the card fabrication process in
accordance with an exemplary embodiment of the present
invention;
[0022] FIG. 4 is a graph of energy v. wavelength for the reflection
and transmission of IR film in accordance with an exemplary
embodiment of the present invention;
[0023] FIG. 5 is a graph of a typical IRED (infrared emitting
diode) source in an ATM having a wavelength in the range of about
820-920 nm or 900-1000 nm in accordance with an exemplary
embodiment of the present invention;
[0024] FIG. 6 is a graph of a spectral sensitivity curve of a
typical phototransistor having a wavelength in the range of about
400 nm-1100 nm in accordance with an exemplary embodiment of the
present invention
[0025] FIGS. 7A-7I show various embodiments of card layers in
accordance with an exemplary embodiment of the present
invention;
[0026] FIG. 8 is a schematic diagram of an exemplary sensor
mechanism within an ATM in accordance with an exemplary embodiment
of the present invention;
[0027] FIG. 9 is an exemplary reflection and transmission monitor
with various optical components for vacuum evaporation in-line roll
coating operations for monitoring the IR film in accordance with an
exemplary embodiment of the present invention;
[0028] FIG. 10 shows an exemplary system for chemical vapor
deposition of PET film in accordance with an exemplary embodiment
of the present invention;
[0029] FIG. 11 shows exemplary embodiments of layers for card
construction in accordance with an exemplary embodiment of the
present invention;
[0030] FIG. 12A shows exemplary film bond strengths on a graph of
strength (lb/in) v. film bond for various film bonds in accordance
with an exemplary embodiment of the present invention;
[0031] FIG. 12B shows exemplary bond strengths at the film
interfaces on a graph of strength (lb/in) v. film interface for
various film interfaces in accordance with an exemplary embodiment
of the present invention;
[0032] FIG. 13 shows exemplary IR ink ingredients which exhibit a
green color in accordance with an exemplary embodiment of the
present invention;
[0033] FIG. 14 shows measurements related to these exemplary green
cards in accordance with an exemplary embodiment of the present
invention;
[0034] FIG. 15 shows exemplary ATM test results for the exemplary
green cards in accordance with an exemplary embodiment of the
present invention;
[0035] FIG. 16 shows an example of the transmission density of
exemplary green cards in a graph of percent transmission v.
wavelength in accordance with an exemplary embodiment of the
present invention; and,
[0036] FIGS. 17A-17I show exemplary test results for various card
embodiments in a graph of percent transmission v. wavelength (nm)
in accordance with an exemplary embodiment of the present
invention.
DETAILED DESCRIPTION OF DETAILED EMBODIMENTS
[0037] In general, the present invention allows for the
identification and detection of various articles, wherein the
articles include materials having machine recognizable compounds.
The articles include, for example, transaction cards, documents,
papers and/or the like. The materials include, for example,
coatings, films, threads, plastics, inks, fibers, paper,
planchettes, and/or the like.
[0038] In an exemplary embodiment, the machine recognizable
compounds are optically recognizable compounds containing infrared
blocking (absorbing, refracting, diffusing, reflecting or otherwise
blocking) ingredients. The optically recognizable compounds may be
invisible, visible, or colored to produce a desired effect and/or
they may contain other detectable compounds, such as, for example,
UV-Fluorescent or IR-Fluorescent features. The optical compounds
preferably have good stability, resistance properties, durability
and other physical properties, such as good appearance,
flexibility, hardness, solvent resistance, water resistance,
corrosion resistance and exterior stability. Moreover, the use of
such compounds typically does not interfere with UV compounds that
may be present in many substrates. One skilled in the art will
appreciate that the optically recognizable compound is any
chemical, solution, dye, ink substrate, material and/or the like
which is recognizable by a sensor. In an exemplary embodiment, the
optically recognizable ink is an infrared ink which blocks, absorbs
or reflects most infrared light, but transmits most other
wavelengths of light.
[0039] In an exemplary embodiment, the optically recognizable
compound is incorporated into a material in the form of a film,
plastic, fiber, ink, concentrate, thermoplastic or thermoset
matrix, thread, planchette, and/or other medium which contains in
the range of about 0.001 to 40.0 wt. (%) of a compound derived from
organic or inorganic materials. The infrared ink may be applied to
card 5 (see FIG. 1) by, for example, a screen printing process or
any other printing or coating means such as lithography, gravure,
flexo, calender coating, curtain coating, roller coating and/or the
like. An exemplary screen printing process utilizes a screen press
equipped with drying equipment (UV curable or convection heat) and
a screen with a specific mesh size of about 80 lines/cm. The IR ink
is printed across any portion of the entire card surface of plastic
using a silk screen press, as described below. Because the relative
eye sensitivity of an ordinary observer for a specified level of
illumination is between around 400-770 nm, infrared ink at over 770
nm is preferable because it is invisible to the human eye in normal
white light. As such, the invisible infrared material will not
substantially obscure the transparent surface of card 5.
Additionally, the exemplary ink withstands card production
temperatures of about 200 F to 400 F degrees and includes a "light
fastness period" (which is the resistance of the ink to fade or
degrade in the presence of any light, and specifically, UV light)
of about at least three years under normal credit card usage
conditions. Moreover, the exemplary ink blocks, absorbs or reflects
the spectral output of IRED's, such as, for example, the Sankyo
Seiki LED's, which is about 800-1000 nm. The exemplary ink also
limits the light reaching the phototransistors, so the presence of
a clear card having the ink is detected in a transaction machine,
such as, for example, a card grabbing-type ATM machine.
[0040] Exemplary compositions of the machine recognizable compounds
of the present invention comprise a mixture of a wide variety of
compounds. The active compounds are derived of inorganic,
organometallic, ore organic layered materials or rare earth
compounds, most commonly rare earth oxides, oxysulfides or
oxyhalides. The compounds are relatively inert, so the effects on
the performance properties of the final product are minimized. The
infrared compound comprises either a dye, layered material, pigment
and/or encapsulated pigment that is dispersed in a particular
medium which can be incorporated into a wide variety of end-usable
products. The particle size of the infrared compound allows the
materials (plastic, thread, ink, etc.) to optimally dispersed or
dissolved and uniformly exist within the articles which it is
incorporated.
[0041] Conventionally known infrared materials comprising layered
dielectric and metallic materials or doped rare-earth materials can
be effectively used as pigments for compounds in accordance with
exemplary embodiments of the present invention. In this context,
the pigments or dyes absorb specific wavelengths of energy and may
change one wavelength of energy to another. The energy conversions
or absorptions may be above or below any stimulation within the
electromagnetic spectrum. The compounds may absorb specific
wavelengths of light or change from one color to another or the
compounds may change from invisible to visible and/or the like. The
infrared compounds of the present invention are thus incorporated
into a system which reversibly changes one wavelength of energy to
another, hence causing a "fingerprint"--type of detectable feature
within the articles.
[0042] Moreover, the prepared films or materials can be mixed with
a binder to form infrared compounds for use in threads, fibers,
coatings, and the like. Binders that can be incorporated in the
present invention include conventional additives such as waxes,
thermoplastic resins, thermoset resins, rubbers, natural resins or
synthetic resins. Such examples of such binders are, polypropylene,
nylon, polyester, ethylene-vinyl acetate copolymer, polyvinyl
acetate, polyethylene, chlorinated rubber, acrylic, epoxy,
butadiene-nitrile, shellac, zein, cellulose, polyurethane,
polyvinylbutyrate, vinyl chloride, silicone, polyvinyl alcohol,
polyvinyl methyl ether, nitrocellulose, polyamide, bismaleimide,
polyimide, epoxy-polyester hybrid and/or the like. Films that can
be used include polyester, polyvinylchloride, polypropylene,
polyethylene, acrylic, polycarbonate and/or the like. As discussed
below, any film can be laminated or adhered to common card articles
using heat, adhesives, or a combination of both.
[0043] If the content of the compound is too low, adequate blocking
may not be achieved and the phototransistor may not send the proper
signal to the capture device, which will mean that the card will
not be detected. Therefore, the infrared compounds are usually
present in the composition at a total amount from about 1 PPM to
80.0 wt. (%), and preferably from about 0.25%-25.0% by weight.
Moreover, the present invention contemplates that other materials
such as, for example, UV absorbers, reflectors, antioxidants,
and/or optical brighteners, may be add in order to achieve better
resistance properties, aesthetics, or longevity of the
materials.
[0044] Particularly, other materials may be added to allow for
color shifts from one color to another color after stimulation.
Commonly employed materials such as dyes, pigments, fluorescent
dyes, luminous pigments, and/or the like, can be used to promote
reversible color changes from one color state to another color
state. Such materials can be incorporated directly with the
infrared compounds during initial processing or may be added after
the infrared compounds have been processed. The use of materials
such as solvents, water, glycol and/or the like can be added to
adjust rhelogical properties of the material. Also, the use of
surfactants, defoamers, release agents, adhesion promoters,
leveling agents, and/or the like may be added to the formulations
for improved processing properties. Optical brightening materials
may also be added to ensure whiteness in a colorless state and to
maintain a low level of contrast between many substrates where
infrared compounds are located.
[0045] Fibers of various materials are used either in a continuous
manner or single fibers can be incorporated into a wide variety of
materials. The present invention contemplates, for example, natural
fibers, synthetic fibers, copolymer fibers, chemical fibers, metal
fibers, and/or the like. Examples of these fibers may be nylon,
polyester, cotton, wool, silk, casein fiber, protein fiber,
acetalyated staple, ethyl cellulose, polyvinylidene chloride,
polyurethane, acetate, polyvinyl alcohol, triacetate, glass, wood,
rock wool, carbon, inorganic fibers, and/or the like. Such fibers
can be incorporated or mixed into other types of materials such as
paper pulp, plastic label stock, plastic materials, and the like.
Such materials can be used alone in a continuous manner or can be
used as mono- or di-filaments in other materials.
[0046] Moreover, the infrared materials that are incorporated into
plastics can be used with a wide variety of materials, such as, for
example, nylon, acrylic, epoxy, polyester, bismaleimide, polyamide,
polyimide, styrene, silicone, vinyl, ABS, polycarbonate, nitrile,
and/or the like. As such, the compounds that are incorporated into
fibers, plastics, film and/or the like, may be processed directly
to a suitable form in a single- or multi-process application. Such
compounds can be added into a formulation in the form of a single
ingredient or in the form of a master-batch that is then processed
in a similar manner to normal processing operations of compounds.
Processing of such compounds includes the use of continuous mixers,
two- or three-roll mills, extrusion, and/or other melt-compounding
methods of dispersion. While in an exemplary embodiment, the thread
can be woven or non-woven, the infrared materials may be extruded
directly into a thermoplastic matrix and drawn directly into the
form of a thread that can be used in a continuous manner or
sectioned in the form of a fiber or plastic film.
[0047] The exemplary infrared compounds are deposited onto films of
various compositions and can be used in most card applications.
Moreover, the infrared compounds in accordance with the present
invention can be used alone or blended with other materials at
ranges from 0.001 to 50.0 parts by weight, but most preferable from
1.0 to 15.0 parts by weight.
[0048] A particularly preferred infrared compound is a multilayer
polymeric film manufactured by 3M Company (Minneapolis, Minn.), and
described in U.S. Pat. No. 5,882,774 entitled "Optical Film", U.S.
Pat. No. 6,045,894 entitled "Clear to Colored Security Film", and
U.S. Pat. No. 6,049,419 entitled "Multilayer Infrared Reflecting
Optical Body", each of which is incorporated herein by reference in
their entireties. Specifically, the multilayer polymeric film is
either a birefringement dielectric multilayer film or an isotropic
dielectric multilayer film designed to reflect infrared radiation,
i.e., electromagnetic radiation commonly known to have a wavelength
longer than visible light, specifically above about 700 nm.
[0049] The particularly preferred film utilized in the present
invention comprises at least two layers and is a dielectric optical
film having alternating layers of a material having a high index of
refraction and a material having a low index of refraction.
Although the film may be either birefringement or isoptropic, it is
preferably birefringement, and is designed to allow the
construction of multilayer stacks for which the Brewster angle is
very large or is nonexistent for the polymer layer interfaces. This
feature allows for the construction of multilayer mirrors and
polarizers whose reflectivity for p-polarized light decreases
slowly with angle of incidence, is independent of angle of
incidence, or increases with angle of incidence away from the
normal. As a result, the multilayer films have high reflectivity
over a wide bandwidth.
[0050] Specific examples of such films are described in U.S. patent
Ser. No. 08/402,201, filed Mar. 10, 1995, and U.S. patent Ser. No.
09/006,601 entitled "Modified Copolyesters and Improved Multilayer
Reflective Film", filed on Jan. 13, 1998. In addition, U.S. Pat.
No. RE 3,034,605 describes films which prevent higher order
harmonics that prevent color in the visible region of ft spectrum.
Other suitable films include the films described in U.S. Pat. No.
5,360,659, which describes a two component film having a six layer
alternating repeating unit that suppresses reflections is in the
visible spectrum (about 380 nm to about 770 nm) while reflecting
light in the infrared wavelength region of between about 770 nm to
about 2000 nm.
[0051] Multilayer polymeric films can include hundreds or thousands
of thin layers and may contain as many materials as there are
layers in the stack. For ease of manufacturing, preferred
multilayer films have only a few different materials. A preferred
multilayer film, as noted above, includes alternating layers of a
first polymeric material having a first index of refraction, and a
second polymeric material of a second index of refraction that is
different from that of the first material. The individual layers
are typically on the order of about 0.05 .mu.m to about 0.45 .mu.m
thick. Preferably, the number of individual layers in the optic
film may preferably range from about 80 to about 1000 layers,
although other numbers are contemplated in the present invention.
In addition, the optical film may be as low as about 0.5 mil thick
to as high as about 20.0 mils thick.
[0052] The multilayer films useful in the present invention may
comprise alternating layers of crystalline naphthalene dicarboxylic
acid polyester and another selected polymer, such as copolyester or
copolycarbonate, wherein each of the layers have a thickness of
less than about 0.5 .mu.m. Specifically, polyethylene
2,6-naphthalate (PEN), polybutylene 2,6-naphthalate (PBN), or
polyethylene terephthalate (PET) are typically used. Adjacent pairs
of layers (one having a high index of refraction and the other a
low index) preferably have a total optical thickness that is
{fraction (1/2)} of the wavelength of the light desired to be
reflected. However, other ratios of the optical thicknesses within
the layer pairs may be chosen as is apparent to one having ordinary
skill in the art. A preferable optic film may be as low as about
0.5 mil having alternating layers of PET and polymethylmethacrylate
(PMMA).
[0053] Although the optical film described above is particularly
preferred, any other optical film may be utilized in the present
invention that effectively absorbs, refracts, diffuses, reflects or
otherwise blocks eletromagnetic radiation of a range or a plurality
of ranges of wavelengths, but transmits electromagnetic radiation
of another range or plurality of wavelengths, such as, for example,
blocking the transmission of infrared radiation, but transmitting
visible radiation, and the present invention should not be limited
as herein described. Other suitable optical films may be sized as
apparent to one having ordinary skill in the art.
[0054] The present invention will now be illustrate in greater
detail with reference to the following examples, comparative
examples, test examples and use examples. As disclosed in the
examples, tests and graphs herein, the resulting inks sufficiently
block IR radiation from phototransistor detection. It is understood
that the present invention is not limited thereto. For example, one
skilled in the art will appreciate that, in any of the examples,
the ink may contain other materials for different optical effects
or authentication purposes.
EXAMPLE 1
[0055] The present example includes about 2% Epolin VII-164 dye and
about 98% Tech Mark Mixing Clear, produced by Sericol, Inc. 980.0 g
of Tech Mark solvent evaporative screen ink is mixed on a
high-speed disperser. While mixing, 20.0 g of Epolight VII-164 dye
is dissolved completely. The resulting ink has a viscosity of about
3.2 Pa.S at 25 C degrees and is printed using a screen process. The
screen process includes a 305 polymer screen onto both sides of
clear PVC 13.0 mil film.
EXAMPLE 2
[0056] The following ink was produced by adding about 15.0 lbs of
Epolight VII-164 and about 20.0 lbs of Epolight VI-30 to about 965
lbs. of TM Mixing Clear. The mixture was dispersed for about 40
minutes. The resulting mixture was coated on PVC core plastic using
an 80 line/cm polyester screen. The resulting coating exhibited
high absorbtivity from 780 nm to 1070 nm with low visible
absorption. Card core, magnetic stripe and lamitate were assembled
and the entire assembly was placed in Burckle Stack Lamination Unit
at a temperature of about 280 F.
EXAMPLE 3
[0057] A concentrate of about 30.0 g. Epolight VII-172 was blended
with about 700.0 g. of polyvinylchloride plastic. The resulting
mixture was extruded at about 260 F, air cooled and pelletized.
About 1.0 lb of the resulting pellets were combined with about 99.0
lbs of PVC. Klockner Pentaplast provided calendered sheets of
approximately 0.13 inches. Cards were fabricated using said sheets.
These cards exhibited sufficenent obsorption in the IR region from
800 nm to 1000 nm. The cards were detected by a Sankyo ATM capture
device.
EXAMPLE 4
[0058] Multi-Layer PET plastic with sufficient optical properties
was combined into a card construction. The PET plastic was provided
by 3M Co. (Minneapolis, Minn.), as described above. The resultant
card exhibited sufficient optics such that an ATM device detected
the card.
ADDITIONAL EXAMPLES
[0059] Additional examples of IR ink formulations are disclosed in
FIG. 13. The IR ink examples in FIG. 13 exhibit a visible green
color. Moreover, FIG. 14 shows measurements related to these
exemplary cards, including, for certain wavelength ranges,
transmission density, ATM readability and ISO compliance. FIG. 15
shows exemplary test results for the exemplary green cards wherein
samples of the cards were inserted into ATMs of various
manufacturers. The tests resulted in positive ATM detection of the
exemplary cards. Furthermore, FIG. 16 shows an example of the
transmission density of exemplary green cards in a graph of percent
transmission v. wavelength (the graph also indicates the ISO
specifications for the card).
[0060] FIGS. 17A-17I show exemplary test results for various card
embodiments in a graph of percent transmission v. wavelength (nm).
For example, with respect to FIG. 17A, the quality assurance of IR
ink on PVC with no text is tested wherein a curve represents one of
four corners of an exemplary card. Subsequent curves represent
another card sample which was selected after an interval of card
production, such as, for example, after about 50 cards. FIG. 17B
shows the percent transmission of different wavelengths of light
through cards having different ink formulations, wherein each curve
represents a card with a different ink formulation.
[0061] FIGS. 17C-17I represent various spectra of films, coatings,
cards, etc which demonstrate the ability of the materials used in
the card constructions to block sufficient quantaties of infrared
radiation and transmit visible light in order to produce cards
described in the embodiement. The mechanism of blocking may be
absorption, reflection, diffusion, dispersion or other methods of
blocking radiation in the electromagnetic spectrum.
[0062] In addition to the IR inks, the optically recognizable
compound may alternatively be a film or hot mirror which also
blocks (absorbs or reflects) infrared light, but transmits all
other wavelengths of light. In an exemplary embodiment, the film is
set between the front sheet 10 and back sheet 12. FIG. 4 is a graph
of energy v. wavelength for the reflection and transmission of an
exemplary IR film in accordance with an exemplary embodiment of the
present invention. FIG. 4 shows that, while the visible light is
transmitted through the film, the infrared light is blocked at
higher wavelengths and a substantial amount of infrared light is
reflected.
[0063] The optically recognizable compounds may be incorporated
into plastic products, films, products, documents or other articles
which may inhibit detection via phototransistors, CCD's, and/or the
like. The material can be incorporated into a transaction card via
a film, plastic, printing ink, coating or other application medium
by grinding or the use of dispersed or deposited material into a
liquid, paste or other type of medium. To minimize environmental
damage to the ink, such as the ink being scratched, the ink is
preferably applied directly onto the plastic sheets under the
laminate (described below in step 170). Moreover, the infrared ink
may be applied on the inside or outside surface of the plastic
sheets.
[0064] In an exemplary embodiment, incorporating the optically
recognizable compound into an article may not require a separate
printing unit, modifications to existing processing equipment or an
additional operational step. Particularly, the fabrication of the
articles, such as a transaction card, utilizes existing equipment
which incorporate colorants anyway, so the application of the
optically recognizable compounds to the existing colorants do not
add extra equipment or steps to the process.
[0065] In a further exemplary embodiment, the optically
recognizable compounds block light which is detectable by machines.
More particularly, the machines suitably detect the presence of a
card via infrared interference at one or several wavelengths. In an
exemplary embodiment, detection of materials may include the
production of a visual effect when the materials are interrogated
with invisible infrared radiation from the proper instrument, and
when such radiation contacts the infrared material, a visual
effect, such as a colored light, can be seen. Alternatively, the
materials may be detected by a remote detector that will indicate
the presence of the materials. Detection or authentication of the
materials occurs above and below the stimulation wavelength of the
reading device. As such, once the optically recognizable material
has been detected, the detection device may then provide the user
with a positive identification signal, which is preferably located
on or near the detection device.
[0066] In an exemplary embodiment, the detection of IR materials
trigger the sensors in ATM machines. In particular, with respect to
FIG. 8, the present invention allows for the passage of a greater
percentage of visible light (from about 400 nm to 700 nm), which
allows the card to appear translucent in nature, while allowing for
the blockage of certain light (from about 700 nm and above) to
allow the phototransistors in ATM's to detect that a card has been
inserted into the carriage mechanism. As discussed above, an
exemplary ATM sensing device includes an IRED, a filter and a
phototransmitter.
[0067] In addition to triggering the sensors in ATM machines,
translucent card 5 can be used with any magnetic stripe or smart
card reader. The reader system can include a card reader/writer, a
point-of-sale terminal, ATM or any other acceptance device. In an
exemplary embodiment, card 5 is used in conjunction with a reader
which, not only detects the existence of the card, but also
illuminates the transparent portion of card 5 when the card is
inserted into the reader. The illumination source can be either an
incandescent or solid state source (infrared emitting diode or
laser). In operation, when the card is inserted into the acceptance
device, the edge of the card presses against the illumination
assembly (or activates a switch, interrupts a beam, etc.).
Depending upon the application of the card, the illumination source
can be under the control of the acceptance device or external
software. Thus, the illumination source can flash or display a
particular color if directed by the external software program.
Additionally, depending on the structure of the card, the
illumination source could be used to excite an embedded design
useful for security or product enhancement
[0068] As discussed above, the optically recognizable compounds may
be incorporated into any type of article. An exemplary article is a
transaction card which may itself include any number of numerous
features. In an exemplary embodiment, the present invention
includes, generally, a transaction card 5 comprised of base
containing opaque, transparent or translucent plastic layers 10, 12
and multiple features affixed to the card 5 such as text 30, 32,
34, logos 50, embossed characters 35, magnetic stripe 42, signature
field 45, holographic foil 15, IC chip 20 and opacity gradient 25
(FIGS. 1 and 2).
[0069] Card 5 also includes an optically recognizable compound,
described above, for allowing the transparent or translucent
transaction card 5 to be recognized by card reading devices, such
as ATMs, and/or for allowing the transparent transaction card 5 to
be recognized and counted during card fabrication. The optically
recognizable compound on transparent card 5 is a substantially
invisible or translucent infrared ink, mirror or film which blocks
(absorbs or reflects) infrared light but transmits all other
wavelengths of light (see FIG. 4). Card 5 can be used for credit,
charge, debit, access, identification, information storage,
electronic commerce and/or other functions.
[0070] With respect to FIG. 3, to fabricate card 5 having a front
and back surface in accordance with an exemplary embodiment of the
present invention, a front sheet 10 and back sheet 12 (FIGS. 1 and
2) consisting of a plastic substrate such as, for example, clear
core PVC, are produced (step 100). One skilled in the art will
appreciate that sheets 10 and 12 of card 5 may be any suitable
transparent, translucent and/or opaque material such as, for
example, plastic, glass, acrylic and/or any combination thereof.
Each sheet 10, 12 is substantially identical and is preferably
about 3'.times.4' (622 mm.times.548 mm) and about 0.005-0.350
inches, or more preferably 0.01-0.15 inches or 13.5 mil thick.
[0071] With respect to FIG. 7A, the fabrication of the individual
card sheets includes either direct layout (9 layers) of film or the
use of a sub-assembly (5 layers). An exemplary sub-assembly
consists of 5 layers of film with room temperature tack adhesive
applied over thermoset and thermoplastic adhesives. The resulting
cards comprise (from the card front towards the card back) 2.0 mil
outer laminate (PVC, polyvinylchloride) having the holographic
foil, embossed surface, chip and other indicia on its surface, 9.0
mil printed PVC core with print side out (card front), 2.0 mil PVC
adhesive, 1.7 mil PET GS (extrusion coated
polyethyleneterephthalate--gluable/stampable) manufactured by
D&K (525 Crossen, Elk Grove Village, Ill. 60007), 2.0 mil PET
IR blocking film, 1.7 mil PET GS, 2.0 mil PET adhesive, 9.0 mil
printed PVC core with the print side out (card back), and 2.0 mil
outer back laminate with a signature panel, applied magnetic stripe
and other indicia. Optimally, the PET IR blocking film is
fabricated in the middle of the layers to balance the card and
minimize warping of the resulting card product. Other exemplary
embodiments of the layers are shown in FIGS. 7B-7H.
[0072] Specifically, FIG. 7G illustrates an alternate embodiment of
the individual transaction cards. As with FIG. 7A, card sheets may
be constructed as described in FIG. 7H. Each card sheet may include
nine layers of film or the use of a five layer subassembly. The
resulting cards comprise (from the card front towards the card
back) about 2.0 mil outer laminate (PVC) having the holographic
foil, embossed surface, chip and/or other indicia on its surface,
about 9.0 mil printed PVC core with print side out (card front),
about 1.0 mil oriented PVC, about 3 mil adhesive (1 mil PET with 1
mil adhesive on each side), about 2.0 mil PET IR blocking film, as
described above, about 3.0 mil adhesive (1 mil PET with 1 mil
adhesive on each side), about 1.0 mil oriented PVC, about 9.0 mil
printed PVC core with print side out (card back), and about 2.0 mil
outer PVC laminate comprising a signature panel, applied magnetic
stripe and/or any other indicia apparent to one having ordinary
skill in the art. As with the card described in FIG. 7A, the PET IR
blocking film is fabricated in the middle of the layers to balance
the card and minimize warping of the resulting card product.
[0073] The adhesive layers described above with reference to FIG.
7G (the 3.0 mil adhesive) that may be disposed on either side of
the 2.0 mil PET IR blocking film preferably comprise a first layer
of a polyester (1.0 mil PET) having second and third layers of a
polyester-based adhesive disposed on either side of the first layer
of polyester. The polyester-based adhesive layers may each be about
1.0 mil. Preferably, the polyester-based adhesive layers exhibit
excellent adhesion to polyester and PVC, in that it binds to both
the PET IR blocking film on one side of the 3.0 mil adhesive and
the 1.0 mil oriented PVC layer on the other side. Specifically, a
preferable material that may be used as the polyester-based
adhesive is Bemis Associates Inc. 5250 Adhesive Film.
Alternatively, another preferably material that may be used as the
polyester-based adhesive is Transilwrap Company, Inc.
Trans-Kote.RTM. Core Stock KRTY.
[0074] The card sheet of FIG. 7G, including the nine layers of film
and/or the use of a five layer subassembly, as described above, may
be constructed together by a lamination process as is known to
someone having ordinary skill in the art using heat and pressure. A
preferred method of constructing the cards as described in FIG. 7H
utilizes a two-step lamination cycle, wherein a first hot step
includes laminating the layers of the cards together at a pressure
of about 170 psi at a temperature of about 300.degree. F. for about
24 minutes. A second step includes laminating the layers together
at a pressure of about 400 psi at a diminished temperature of about
57.degree. F. for about 16 minutes. Of course, other methods of
constructing the cards may be utilized.
[0075] Of course, other multilayer films may be utilized that
incorporate an optical film therein (as described above) for
blocking light of one or more ranges of electromagnetic radiation
while allowing another range or ranges of electromagnetic radiation
to be transmitted therethrough. The multilayer films may have any
sequence of layers of any material and thickness to form individual
transaction cards as herein defined.
[0076] FIG. 7I illustrates another exemplary card sheet
construction according to the present invention. Specifically, FIG.
7I illustrates another transparent or translucent card having an IR
blocking optical film incorporated therein, as described above with
reference to FIGS. 7A and 7G. The card sheet construction defined
below may be made via a coextrusion/lamination process.
Specifically, the card sheet comprises a layer of a PET IR blocking
optical film (about 2.0 mils), as described above. An EVA-based
material (about 2.0 mile) may be coextruded onto each side of the
IR blocking film to form a 3-layer subassembly. The 3-layer
subassembly may then be laminated on each side to a printed PVC
layer (each about 11 mils). The card may further have PVC laminate
layers (each about 2.0 mils) disposed on si of the printed PVC
layers thereby forming outside layers of the card.
[0077] Preferable materials that may be utilized as the EVA-based
material that is coextruded to the PET IR blocking film are acid
modified EVA polymers. The acid modified EVA polymers may
preferably be Bynel.RTM. Series 1100 resins. Typically, the
Bynel.RTM. Series 1100 resins are available in pellet form and are
used in conventional extrusion and coextrusion equipment designed
to process polyethylene resins. The Bynel.RTM. Series 1100 resins
have a suggested maximum melting temperature of about 238.degree.
C. However, if adhesion results are inadequate, the melting
temperature may be lowered. The remaining layers of the card may be
laminated to the card as described above, or via any other
lamination process to form a card.
[0078] In addition, FIG. 7H illustrates another exemplary card
sheet construction according to the present invention.
Specifically, FIG. 7H illustrates a transparent or translucent
multilayer transaction card having an IR blocking ink incorporated
therein. The IR blocking ink may be any ink having the
characteristic of blocking IR radiation from being transmitted
through the transaction card. Examples 1 and 2, noted above,
describe two possible ink compositions that may be used. Of course,
others may be used as well and the invention should not be limited
as herein described.
[0079] The card sheet in FIG. 7H may comprise (from the card front
to the card back) an outer layer of about 2.0 mil PVC laminate
having the holographic foil, embossed surface, chip, and/or other
indicia on its surface, about 13.0 mil printed PVC, about 2.0 mil
PVC core, about 13.0 mil printed PVC, and an outer layer of about
2.0 mil PVC laminate comprising a signature panel, applied magnetic
stripe and/or any other indicia apparent to one having ordinary
skill in the art. It should be noted that the PVC core layer
(herein described, according to FIG. 7H, as being about 2.0 mil
thick) may be optional, and may be included if a thicker card is
desired. Of course, the PVC core layer may be any thickness to
create a transaction card having any thickness desired. These cards
may be printed on the core PVC layer with IR blocking ink across
the entire surface of the layer according to the printing methods
described above with respect to Examples 1 and 2, above. Of course,
any other method of printing or IR blocking ink may be utilized in
the transaction according to the present invention.
[0080] After the card sheets are laminated, according to the method
described above or via any other method, the sheets are cut into
individual cards by a known stamping process, including any
necessary curing, burrowing, heating, cleaning, and/or sealing of
the edges. Each individual transaction card is about
2.5".times.3.0", and therefore conform to ISO standards for
transaction card shape and size.
[0081] Moreover, FIG. 11 details exemplary embodiments of
layers/sheets for card construction, including layer number,
material, layer thickness (in mil), source/manufacturer of the
material, comments regarding bond strength data and total thickness
(in mil). Additionally, with respect to FIG. 12A, the film bond
strength is indicated on a graph of strength (lb/in) v. film bond
for various film bonds. With respect to FIG. 12B, the bond strength
at the film interfaces is indicated on a graph of strength (lb/in)
v. film interface for various film interfaces.
[0082] After eventually combining the sheets (step 160), by
preferably adhering the front sheet 10 on top of the back sheet 12,
the total thickness of the transaction card 5 is about 0.032 in.
(32 mil.), which is within the ISO thickness standard for smart
cards. Because the IC chip 20 is eventually embedded into the
surface of the substrate (step 195), and the surface of chip 20 is
co-extensive with the outer surface of the front sheet 10, the IC
chip 20 does not affect the thickness of the overall card 5.
Moreover, the about 3'.times.4' sheets include markings which
define the boundaries of the individual cards 5 which will be cut
from the sheet. Each exemplary sheet yields over 50 transaction
cards (typically 56 cards), wherein each card 5 is within the ISO
card size standard, namely about 2".times.3.5".
[0083] In general, an exemplary process for construction of card 5
having an IR film includes chemical vapor deposition of PET film
which has optimal visible and infrared properties (step 105). The
chemical deposition is preformed by a Magnetron Machine
manufactured by the Magnetron Company. With respect to FIG. 10, the
process incorporates a roll chemical vapor deposition sputtering
system with three coating zones. The Magnetron roll vapor
deposition machine deposits evaporation batches containing Ag, Au
and Indium oxide onto optical grade polyethyleneterepalate using
chemical vapor deposition. The Ag/Au/Indium layers are about 100
angstroms each and, depending on the lower wavelength reflections,
about three to five layers exist. More details related to vacuum
coating, solar coating and Magnetron sputtering can be found in,
for example, "Handbook of Optical Properties, Volume I, Thin Films
for Optical Coatings" edited by Rolf Hummel and Karl H. Guenther,
1995, CRC Press, Inc, the entire contents of which is hereby
incorporated by reference.
[0084] Next, plasma or flame treatment is applied to the PET film
for surface tension reduction of the film (step 110). During the
deposition and assembly of the layers, the IR film is monitored to
optimize the IR blocking spectrum. Thus, the film is then tested
against a standard by using a spectrophotometer to test the visible
and infrared properties of the PET film (step 115). With respect to
FIG. 9, a reflection and transmission monitor with various optical
components for vacuum evaporation in-line roll coating operations
is utilized to monitor the IR film. In-line spectrophotometric
monitoring is part of the vapor deposition process. Transmission at
various wavelengths is monitored during the entire run. A tack
adhesive is applied to PET GS
(polyethyleneterephthalate--gluable/stampable) (step 120) and a
pressure laminate is applied to the Indium Oxide metal surface of
the PET IR blocking film (step 125). Next, a tack adhesive is
applied to the PET side of the IR blocking film (step 130) and a
pressure laminate is applied to the PET GS (step 135). Exemplary
lamination conditions include 280 F degrees and 600 psi for 22
minutes, then cooled under pressure for about 18 minutes. A heat
seal adhesive is applied to both outer sides of the PET GS, or
alternatively, a PVC adhesive is applied to both outer sides of the
PET GS (step 140).
[0085] In an exemplary embodiment, certain compounds are printed
over the surface of sheets 10 and 12. One skilled in the art will
appreciate that the printing of the text 30, 32, 34, logos 50,
optically recognizable ink and opacity gradient 25 may be applied
to any surface of card 5 such as, for example, the front 10 face,
the rear 12 face, the inside or outside surface of either face,
between the two sheets of base material and/or a combination
thereof. Moreover, any suitable printing, scoring, imprinting,
marking or like method is within the scope of the present
invention.
[0086] The opacity gradient 25 and optically recognizable ink are
printed onto the sheets by a silk screen printing process (step
150). With respect to the opacity gradient 25, the exemplary
gradient is comprised of a silver pearl ink gradation having an ink
stippling which is more dense at the top of card 5 and gradually
becomes less dense or clear as it approaches the bottom of card 5.
One skilled in the art will appreciate that the opacity gradient 25
can be any density throughout the gradient 25 and the gradient 25
can traverse any direction across card 5 face. The opacity gradient
25 can be formed by any substance which can provide a similar
gradient 25 on card 5. The exemplary ink gradient 25 for each card
5 is printed using known printing inks suitably configured for
printing on plastic, such as Pantone colors. In an exemplary
embodiment, the ink used for the stippling 25 is a silver pearl ink
and is applied to the outside surface of each plastic sheet. Ink
gradient 25 is printed on the surface of each of the sheets using a
silk screen printing process which provides an opaque, heavier ink
coverage or using offset printing process which provides halftone
images in finer detail. The words "American Express" are printed in
Pantone 8482 using a similar silkscreen process.
[0087] More particularly, with respect to silk screen printing,
artwork containing the desired gradient 25 is duplicated many times
to match the number of individual cards 5 to be produced from the
sheets. The duplicated artwork is then suitably applied to a screen
by any suitable known in the art photo-lithographic process and the
screen is then developed. The screen is placed over the sheet and
ink is suitably washed across the surface of the screen. The
exposed portions of the screen allow the ink to pass through the
screen and rest on the sheet in the artwork pattern. If multiple
colors are desired, this process can be repeated for each color.
Moreover, other security features are optionally silk printed on
card 5 such as, for example, an invisible, ultraviolet charge card
logo (visible in black light) is printed in a duotone of Pantone
307 and 297 using offset and silk screen presses.
[0088] The text 30, 32, 34 and logo 50 are printed on the outside
surface of each sheet by a known printing process, such as an
offset printing process (step 155) which provides a thinner ink
coverage, but clearer text. More particularly, with respect to
offset printing, the artwork is duplicated onto a metal plate and
the metal plate is placed onto an offset press printing machine
which can p up to four colors during a single . The offset printed
text includes, for example, a corporate name 30, a copyright notice
33, a batch de number 34, an "active-thru" date 32, contact
telephone numbers, legal statements (not shown) and/or the like.
The exemplary offset text is printed in 4 DBC in opaque white ink
or a special mix of Pantone Cool Gray 11 called UV AMX Gray.
[0089] Because the resulting card 5 may be transparent, the text
can be seen from both sides of card 5. As such, if the text is only
printed on one sheet, the text may be obscured when viewing the
text from the opposite side of card 5 (in other words, viewing the
text "through" the plastic substrate). To minimize the obscuring of
the text, the front sheet 10 is printed on its outside surface with
standard format text and the back sheet 12 is printed on its
outside surface with the same text, but the text is in "reverse"
format. The back 12 text is aligned with the text on the front face
10, wherein the alignment of the text is aided by card 5 outline
markings on the full sheet. Certain text or designs which may be
obscured by an compound of card 5 (magnetic stripe 40, chip 20,
etc.) may be printed on only one sheet. For example, in an
exemplary embodiment, the corporate logo 50 is printed on only one
sheet and is located behind the IC chip 20, thereby being hidden
from the front 10 view and hiding at least a portion of the IC chip
20 from the back 12 view. One skilled in the art will appreciate
that any of the offset printing can occur on the outside or inside
surface of the sheets.
[0090] The sheet of laminate which is applied to the back 12 of
card 5 (step 170) preferably includes rows of magnetic stripes 40,
wherein each magnetic stripe 40 corresponds to an individual card
5. The magnetic stripe 40 extends along the length of card 5 and is
applied to the back 12 surface, top portion of card 5 in conformity
with ISO standards for magnetic stripe 40 size and placement.
However, the magnetic stripe 40 may be any width, length, shape,
and placed on any location on card 5. The two track magnetic stripe
40, including the recorded information, can be obtained from, for
example, Dai Nippon,1-1, Ichigaya Kagacho 1-chome, Shinjuku-ku,
Tokyo 162-8001, Japan, Tel: Tokyo 03-3266-2111. In an exemplary
embodiment, the magnetic stripe is applied to the outer laminate
using a tape layer machine which bonds the cold peel magnetic
stripe to the outer laminate roll with a rolling hot die and at
suitable pressure. The roll is then cut into sheets at the output
of the tape layer before the card layers are assembled and the
stripe is fused to the card during the lamination process.
[0091] Although prior art magnetic stripes 40 in current use are
black, in a particularly exemplary embodiment, the magnetic stripe
40 of the present invention is a silver magnetic stripe 40.
Exemplary silver magnetic stripe 40 is 2750 oersted and also
conforms to ISO standards. Moreover, the silver magnetic stripe 40
includes printing over the magnetic stripe 40. The printing on the
magnetic stripe 40 can include any suitable text, logo 50, hologram
foil 15 and/or the like; however, in an exemplary embodiment, the
printing includes text indicative of an Internet web site address.
Dai Nippon Printing Co., Ltd (more information about Dai Nippon can
be found at www.dnp.co.jp) prints a hologram or text on the mag
stripe using, for example, the Dai Nippon CPX10000 card printer
which utilizes dye sublimation retransfer technology having a
thermal head which does not contact the card surface. The card
printer utilizes the double transfer technology to print the image
with the thermal head over a clear film and then re-transferring
the printed image onto the actual card media by heat roller. The
printing of information on the surface of the magnetic stripe 40 is
preformed by, for example, American Banknote Holographics, 399
Executive Blvd., Elmsford, N.Y. 10523, (914) 592-2355. More
information regarding the printing on the surface of a magnetic
stripe 40 can be found in, for example, U.S. Pat. No. 4,684,795
issued on Aug. 4, 1987 to United States Banknote Company of New
York, the entire contents of which is herein incorporated by
reference.
[0092] After the desired printing is complete and the magnetic
stripe applied, the front 10 and back 12 sheets are placed together
(step 160), and the sheets are preferably adhered together by any
suitable adhering process, such as a suitable adhesive. One skilled
in the art will appreciate that, instead of printing on two sheets
and combining the two sheets, a single plastic card 5 can be used,
wherein card 5 is printed on one side, then the same card 5 is
re-sent through the printer for printing on the opposite side. In
the present invention, after adhering the sheets together, a sheet
of lamination, approximately the same dimensions as the plastic
sheets, namely 3'.times.4', is applied over the front 10 and back
12 of card 5. After the laminate is applied over the front 10 and
back 12 of the combined plastic sheets (step 170), card 5 layers
are suitably compressed at a suitable pressure and heated at about
300 degrees, at a pressure of between 90-700 psi, with a suitable
dwell time to create a single card 5 device. The aforementioned
card fabrication can be completed by, for example, Oberthur Card
Systems, 15 James Hance Court, Exton, Pa.
[0093] The cards may be constructed by laminating the layers
together using heat and pressure. For example, the transaction
cards may be roll laminated with adhesives, platen laminated, or
other lamination process to laminate the cards together. Processing
temperatures may range from about 200.degree. F. to about 500'
depending on the material used in the layers of the multilayer
transaction card (such as PETG, polycarbonate, or other like
materials). For PVC, the temperatures commonly range from about
270.degree. F. to about 320.degree. F. Pressures may range from
about 50 psi to about 600 psi. Processing times for laminating the
transaction cards of the present invention may range from a few
seconds (1-10 seconds, for example if roll laminated with
adhesives) to up to about an hour if polycarbonate is used as a
material in the multilayer transaction card. For PVC materials, a
hot cycle of about 20 to 30 minutes may be used. Cool cycles may
last about 15 to about 25 minutes for PVC materials.
[0094] In an exemplary embodiment, and especially for IR ink cards,
such as, for example, the card described with respect to FIG. 7H,
the card layers are fused together in a lamination process using
heat and pressure. During the hot press phase, the press is heated
to about 300 F degrees and the pressure builds to about 1000 psi
and holds for about 90 seconds. The pressure then ramps up to about
350 psi over an about 30 second period and holds for 16 minutes at
the same temperature, namely 300 F degrees. The card is then
transferred to a cold press that is at about 57 F degrees. The
pressure builds to about 400 psi and is held for about 16 minutes
as chilled water of about 57 F degrees is circulated in the plates.
The cold press then unloads the card.
[0095] With respect to FIGS. 1 and 2, after the laminate is
applied, a signature field is applied to the back surface 12 of
card 5 (step 175) and the holographic foil 15 is applied to the
front 10 of card 5 (step 190). With respect to signature field 45,
although prior art signature fields are formed from adhering a
paper-like tape to the back 12 of card 5, in an exemplary
embodiment of the present invention, the signature field 45 is a
translucent box measuring about 2" by 3/8" and is applied to the
card using shot-stamp process. The verification of the signature in
signature field 45 by the merchant is often a card 5 issuer
requirement for a merchant to avoid financial liability for
fraudulent use of card 5. As such, the translucent signature field
45 on the transparent card 5 not only allows the clerk to view at
least a portion of the signature field 45 from the front of the
card 5, but the signature view also encourages the clerk to turn
over card 5 and verify the authenticity of the signature with the
signed receipt.
[0096] After the card sheets are laminated, the sheets are cut into
individual cards 5 (step 180) by a known stamping process,
including any necessary curing, burrowing, heating, cleaning and/or
sealing of the edges. The individual transaction cards 5 are about
3".times.4" and conform to ISO standards for transaction card 5
shape and size. In an exemplary embodiment, the laminated sheets of
56 cards are suitably cut in half on a guillotine device, resulting
in two half-sheets of 28 cards. The half-sheets are loaded onto a
card punch machine which aligns the sheets to a die (x and y axes)
using predetermined alignment marks visible to the optics of the
machine. The half-sheets are then fed under the punch in seven
steps. Particularly, a fixed distance feed is followed by another
optic sensor search to stop the feed at the pre-printed alignment
mark, then the machine punches a row of four cards out at one time.
After die cutting and finishing according to standard processing,
the IR reflection properties are verified in-line (step 185) before
application of the holographic foil 15.
[0097] With respect to the application of an exemplary holographic
foil, the holographic foil 15 is adhered to card 5 (step 190) by
any suitable method. In an exemplary embodiment, a substantially
square steel die, which is about 11/4".times.11/4" with rounded
corners and a 0.0007" crown across the contacting surface, stamps
out the individual foils 15 from a large sheet of holographic foil
15. The die is part of a hot stamp machine such that the die is
sent through a sheet of foil 15, cutting the foil 15 around a
particular image and immediately applying the foil 15 with heat to
the front 10 surface of card 5 after the card has been laminated.
The die temperature is in the range of about 300 F..degree. +/- 1
F..degree.. The dwell time is approximately {fraction (1/2)}
seconds and the application speed is set based upon the individual
hot stamp applicator; however, the foregoing temperature and dwell
is identified for a speed of 100 cards per minute. U.S. Pat. Nos.
4,206,965, 4,421,380; 4,589,686; and 4,717,221 by Stephen P. McGrew
provide more details about hot stamping of a holographic image and
are hereby incorporated by reference.
[0098] With respect to the holographic foil 15, the foil 15 can be
any color, contain any hologram, can be applied to any location on
card 5, and can be cut to any size, shape and thickness. In an
exemplary embodiment, the holographic foil 15 sheet preferably
includes a gray adhesive on the bottom side and a blue,
mirror-like, three-dimensional holographic surface on the top side
containing numerous holographic images about 11/4".times.11/4"
each. The exemplary hologram includes a 360 degree viewability and
diffracts a rainbow of colors under white light. The full color
hologram is created by, for example, American Banknote
Holographics.
[0099] The corners of the individual foil 15 are preferably rounded
to minimize the likelihood that the foil 15 will peal away from the
surface of card 5. Moreover, when applied to the card, the blue
holographic surface faces away from card 5 while the gray adhesive
side is applied to card 5 surface. The top surface of the
holographic foil 15 may be created by any suitable method such as
reflection holographics, transmission holographics, chemical
washing, the incorporation of mirror compounds and/or any
combination thereof. The holographic foil 15 can be fabricated by,
for example, American Banknote Holographics, Inc. located at 1448
County Line Road, Huntingdon Valley, Pa., 19006.
[0100] The exemplary holographic foil includes various layers. One
skilled in the art will appreciate that any ordering, combination
and/or composition of these layers which provides a similar
holographic effect is still within the scope of the present
invention. In an exemplary embodiment, the holographic transfer
foil structure includes the following layers: 90 gauge polyester
carrier, release coat, embossable resin, vacuum deposited aluminum,
tie coat and size coat. During the transfer process, the embossable
resin, vacuum deposited aluminum, tie coat and size coat layers are
deposited onto a substrate.
[0101] In an exemplary embodiment, the sheets of holographic foil
15 are transmission holograms suitably created by interfering two
or more beams of converging light, namely an object beam and
reference beam, from a 20 watt Argon laser at 457.9 nm, onto a
positive photoemulsion (spun coat plates using shiply photoresist).
The system records the interference pattern produced by the
interfering beams of light using, for example, a 303A developer.
The object beam is a coherent beam reflected from, or transmitted
through, the object to be recorded which is preferably a
three-dimensional mirror. The reference beam is preferably a
coherent, collimated light beam with a spherical wave front 10.
[0102] The incorporation of the holographic foil 15 onto a
transaction card 5 provides a more reliable method of determining
the authenticity of the transaction card 5 in ordinary white light,
namely by observing if the hologram has the illusion of depth and
changing colors. Thus, to allow the hologram to be viewed with
ordinary, white light, when the hologram is recorded onto the
transaction card 5, the image to be recorded is placed near the
surface of the substrate. Moreover, the hologram is be embossed on
a metalized carrier, such as the holographic foil 15, or
alternatively the hologram may be cast directly onto the
transparent plastic material. When formed on the clear plastic
material, the hologram is made visible by the deposit of a visible
substance over the embossed hologram, such as a metal or ink. More
information regarding the production of holograms on chargecards 5
or the production of holographic foil 15 can be found in, for
example, U.S. Pat. No. 4,684,795 issued on Aug. 4, 1987 to United
States Banknote Company of New York or from the American Banknote
Holographics, Inc. web site at www.abnh.com, both of which are
herein incorporated by reference.
[0103] In an exemplary embodiment, the application of holographic
foil onto vinyl credit cards is accomplished by using a metallized
credit card foil. The foil is un-sized, metallized, embossable,
abrasion, and chemical resistant hot stamping foil on a 1.0 mil (92
gauge) polyester carrier. All of the exemplary materials are tinted
with raw materials supplier color code #563 (blue). The foil is
vacuum metallized with aluminum and has an optical density range of
about 1.60 to 2.00. The optimum foil is free of visible defects and
particulate matter. The foil contains release characteristics of
about 0 to 7 grams based upon release testing unit having a die
face of 300 F degrees, 80 psi, 1.0 seconds dwell, 0.1 seconds delay
in the removal of the carrier at a 45 degree angle. An exemplary
base material is capable of receiving a permanent, high fidelity
(based upon an embossing die of 100%, having at least 70%
diffraction efficiency) impression of the holographic image surface
by embossing with a hard nickel die in the range of about 1600
pounds per linear inch at about 100 pounds air pressure and in the
range of about 200 to 350 F degrees die temperatures. When testing
the embossibility of the base material, the testing includes a
primary and secondary image to assure the embossable coating is
capable of producing an optimal secondary image.
[0104] With respect to the mechanical and chemical durability of
the holographic foil, the foil resists abrasions. As such, after
sizing and stamping the foil onto the vinyl credit card, the
transferred hologram withstands about 100 cycles on the Taber
Abrader using CS-10 wheels and about a 500 gram load before signs
of breakthrough. The foil resists scuffing such that the foil
withstands about 6 cycles on Taber Abrader under the same
conditions without any substantial visual marks, scratches or haze.
The holographic foil also resists any substantial evidence of
cracking the vinyl in the hologram area when embossed on a DC 50000
encoder or an equivalent system.
[0105] Moreover, the embossed, un-sized foil on the polyester
carrier is capable of being stretched 15% without cracking of the
base coat. Moreover, the exemplary vinyl card with the exemplary
hologram withstands 15 minutes in an oven at 110.degree. C. with
the image clearly visible after the test. Additionally, the
exemplary hologram does not show any visible effects after 5 cycles
of 8 hours at 0.degree. and 16 hours at 60.degree. C.
[0106] The exemplary holograms on the vinyl cards also resist
plasticizers, alkalis, acids and solvents. In particular, the cards
with holograms withstand immersion in warm liquid plasticizers
(typically dioctyl phthalate) up to the point of severe swelling of
the card. The image on the card is not substantially affected by
contact with plasticized vinyl for a period of 5 days at 60.degree.
C. With respect to alkalis, the holograms on the cards withstand
approximately 1 hour immersion in 10% ammonium hydroxide at room
temperature without deterioration. Moreover, the hologram does not
show substantial deterioration after 50 hours of immersion at room
temperature in artificial alkaline perspiration (10% sodium
chloride, 1% sodium phosphate, 4% ammonium carbonate, and pH 8.0).
With respect to acids, the exemplary holograms on the cards
substantially withstand approximately 1 hour immersion in 10%
acetic acid at room temperature without substantial deterioration.
Moreover, the exemplary hologram substantially withstand, without
substantial deterioration, 50 hours immersion at room temperature
in artificial acetic perspiration (10% sodium chloride, 1% sodium
phosphate, 1% lactic acid, pH 3.5).
[0107] With respect to solvents, the exemplary holograms on cards
substantially withstand the following: ethylene glycol (100% and
50% in water) with no substantial effects after 4 hours at room
temperature, ethyl alcohol (100% and 50% in water) with no
substantial effect after 4 hours at room temperature, methyl ethyl
ketone has no substantial effect after 1 minute at room
temperature, toluene has no substantial effect up to severe
swelling of the card (30 minutes at room temperature), water has no
substantial effect after 16 hours at 60.degree. C. and concentrated
laundry detergent has no substantial effect after 20 hours at room
temperature.
[0108] Moreover, the exemplary holograms on the vinyl cards do not
show substantial effects after being washed and dried in a
commercial washer and dryer inside a pants pocket at permanent
press settings.
[0109] The charge card substrate is comprised of a vinyl base or
other comparable type material which is suitably capable of
accepting a hot stamping of a hologram without substantially
violating the present composition of the hologram or its coatings.
When adhering the hologram to the vinyl card, the coating exhibits
a consistent blush and is uniform in color, viscosity and free of
contamination. The adhesion of the hologram to the card is also
sufficiently strong enough such that the application of Scotch 610
tape over the hologram which is removed at a 45.degree. angle will
not result in a significant amount of foil removed from the
substrate.
[0110] With respect to the brightness of the image, a diffraction
reading is obtained at a minimum of about 2 microwatts on the
registration blocks. Moreover, with respect to image quality, the
images are substantially free of defects such as large spots,
scratches, wrinkles, mottle, haze, and/or any other defects that
substantially distort the image.
[0111] The final exemplary product is slit at a width of 1{fraction
(53/64)}"+/-{fraction (1/64)}" and length of 10,000 images per
roll. The registration block is located no more than about
{fraction (5/64)}" from the edge of the slit material. All finished
rolls are wound with the metal side facing in on a 3.0" ID core
with a maximum of 3 splices permitted per finished reel and the
registration blocks are 0.125.times.0.125" square.
[0112] After stamping out the individual cards 5 and applying the
holographic foil, the IC chip 20 is applied to card 5 (step 195) by
any suitable method, such as adhesive, heat, tape, groove and/or
the like. More particularly, a small portion of the front 10 of
card 5 is machined out using, for example, a milling process. The
milling step removes about 0.02 mils of plastic from the front 10
surface, such that the routed hole cuts into the two core layers of
plastic, but does not go through the last outer laminate layer of
plastic, thereby forming a 5235HST pocket. IC chip 20 is a 5235
palladium plated with silver, rather than the standard gold
plating. IC chip 20 is applied to the card using a process known as
"potting". Any suitable adhesive, such as a non-conductive
adhesive, is placed into the machined hole and the IC chip 20 is
placed over the adhesive such that the top surface of the IC chip
20 is substantially even with the front 10 surface of card 5.
Suitable pressure and heat is applied to the IC chip 20 to ensure
that the IC chip 20 is sufficiently affixed to card 5. The IC chip
20 is any suitable integrated circuit located anywhere on card 5.
In an exemplary embodiment, the IC chip 20 structure, design,
function and placement conforms to ISO standards for IC chips 20
and smart cards 5. The IC chip 20 may be obtained from, for
example, Siemens of Germany.
[0113] After applying the holographic foil 15 and the IC chip 20 to
card 5, certain information, such as account number 35 and "active
thru" 32 date (not shown), are preferably embossed into card 5
(step 200) by known embossing methods. The embossing can be
completed by, for example, Oberthur Card Systems. Although any
information can be embossed anywhere on card 5, in a particularly
exemplary embodiment, the account numbers 35 are embossed through
the holographic foil 15 to reduce the possibility of the transfer
of the holographic foil 15 to a counterfeit card 5 for fraudulent
use. Additionally, although prior art cards 5 include a beginning
and ending validity date, the present card 5 only includes an
"active thru" 32 date, namely a date in which the card expires.
[0114] While the foregoing describes an exemplary embodiment for
the fabrication of card 5, one skilled in the art will appreciate
that any suitable method for incorporating text 30, 32, 34, logos
50, embossed numbers 35, a magnetic stripe 42, a signature field
45, holographic foil 15, an IC chip 20 and opacity gradient 25 (see
FIGS. 1 and 2) onto a substrate is within the scope of the present
invention. Particularly, the holographic foil 15, IC chip 20, logo
50, magnetic stripe 40, signature field 45 or any other compound
may be affixed to any portion of card 5 by any suitable means such
as, for example, heat, pressure, adhesive, grooved and/or any
combination thereof.
[0115] The present invention has been described above with
reference to an exemplary embodiment. However, those skilled in the
art having read this disclosure will recognize that changes and
modifications may be made to the exemplary embodiment without
departing from the scope of the present invention. For example,
various steps of the invention may be eliminated without altering
the effectiveness of the invention. Moreover, other types of card
fabrication, encoding and printing methods may be used such as dye
sublimation retransfer technology and/or double transfer technology
developed by Dai Nippon Printing Company of Japan. These and other
changes or modifications are intended to be included within the
scope of the present invention, as expressed in the following
claims.
* * * * *
References