CN106462782A - 具有选定纹理和着色的交易和id卡 - Google Patents
具有选定纹理和着色的交易和id卡 Download PDFInfo
- Publication number
- CN106462782A CN106462782A CN201580026503.9A CN201580026503A CN106462782A CN 106462782 A CN106462782 A CN 106462782A CN 201580026503 A CN201580026503 A CN 201580026503A CN 106462782 A CN106462782 A CN 106462782A
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- Prior art keywords
- layer
- card
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- metal layers
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Classifications
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
- G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
- G06K19/067—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components
- G06K19/07—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components with integrated circuit chips
- G06K19/077—Constructional details, e.g. mounting of circuits in the carrier
- G06K19/0772—Physical layout of the record carrier
- G06K19/07722—Physical layout of the record carrier the record carrier being multilayered, e.g. laminated sheets
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D7/00—Electroplating characterised by the article coated
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- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/06—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
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- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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Abstract
一种根据本发明制作的卡，其包括与由金属或陶瓷材料构成的厚芯层附接的经特定处理的薄装饰层，其中，薄装饰层设计成向金属卡的表面提供选定的颜色和/或选定的纹理。一种用于在实践本发明中使用的装饰层，其包括：(a)阳极化金属层；或(b)由源自植物或动物物质(如，木材、皮革)的材料构成的层；或(c)混合有激光反应性物质(如，细碎碳)的各种集料粘合剂材料(如，水泥、灰泥、环氧树脂)；或(d)陶瓷层；和(e)晶体织物材料层。这些卡可以是能够以非接触方式和/或经由接触被读取的双接口智能卡。
Description
背景技术
本申请要求基于在2014年5月22日提交的、题为“TRANSACTION AND ID CARDSWITH CONTROLLED COLORING(具有受控着色的交易和ID卡)”、序列号为62/001706的临时申请的优先权，该临时申请的教示通过参引并入本文。本申请还要求基于在2014年11月3日提交的、题为“CERAMIC TRANSACTIONAL AND IDENTIFICATION CARDS WITH CONTROLLEDCOLORING(具有受控着色的陶瓷交易和识别卡)”、序列号为62/074305的临时申请的优先权，该临时申请的教示通过参引并入本文。
本发明涉及具有变化的颜色和纹理的金属卡的制造。具体地，本发明涉及用于生产具有下述金属层的交易和ID卡或者任意类似的文件的装置和方法：该金属层使得卡可以被制成为具有各种颜色和纹理。本发明还涉及具有陶瓷材料芯层的卡和具有装饰性陶瓷层的金属卡。
期望向高端市场提供金属卡或陶瓷卡以赋予持卡人财富感和与众不同感。还期望提供具有不同颜色和纹理的金属卡以进一步增强视觉和触感吸引力并且/或者提供一定程度的个性化。
已知使用物理气相沉积(PVD)来给金属交易卡着色，但是PVD在其颜色范围方面有限并且也相对昂贵。PVD还高度依赖PVD所沉积的基底。PVD是具有高热量的真空过程，并且昂贵的批量操作需要将部件单独地放置和转动以使颜色均匀分布。PVD还使金属经受会使该金属收缩和翘曲的高温。
在一些金属卡中，印刷的PVC层或其他聚合物被用于对卡的外部进行装饰。这些聚合物层的使用具有不希望的特征，如最小印刷厚度、由于聚合物厚度而造成的金属卡的重量损失、以及对不同材料的层合的挑战性。不同厚度和化合物的使用还会使部件由于压板层合期间的不均匀收缩而翘曲或弯曲。
本发明的目的是克服这些问题和其他问题以及使得能够制造具有较宽范围的颜色和纹理的金属卡和/或陶瓷卡。
发明内容
根据本发明制造的卡包括附接至金属、涂覆有陶瓷的金属或聚合物，或实心陶瓷材料的厚芯层的任一侧或两侧的经特定处理的薄装饰层，其中，薄装饰层被设计成为卡的表面提供选定的颜色和/或选定的纹理。用于实现本发明的装饰层包括：(a)阳极化金属层；或(b)源自于植物或动物物质材料(如，木材、皮革)的层；或(c)混合有激光反应性物质(如，细碎碳)的各种集料粘合剂材料(如，水泥(cement)、灰泥(mortar)、环氧树脂)；或(d)陶瓷层；以及(e)晶体织物材料(crystal fabic material)层。这种卡可以是能够以非接触方式和/或经由接触而被读取的双接口智能卡。
根据本发明的金属卡的制造包括对通常薄的装饰层的制备和处理以及将该装饰层附接至厚金属基底；其中，薄装饰层设计成主要为金属卡的正表面而且还为卡的背面提供选定的颜色和/或选定的纹理。
在薄装饰层是阳极化金属层的情况下，该金属层被制备成并处理成具有选定的颜色以赋予卡以颜色。出于若干原因，通过阳极化向金属层添加颜色(着色)比PVD工艺优选。阳极化是将金属表面转变成装饰性的、耐用的、耐腐蚀的阳极氧化物表面的电化学工艺。因此，通过阳极化给金属着色是非常期望的。铝理想地适合阳极化。然而，还可以使用其他有色金属，如镁、钛、锌、铌、钽，或能够被阳极化的任意其他金属来实践本发明。
例如，对于铝膜，阳极氧化物结构来源于铝基底并且完全由氧化铝构成。这种氧化铝并非像涂刷或电镀那样被施加至表面，而是与下面的铝基底完全结合，因此这种氧化铝不会碎裂或剥离。这种氧化铝具有允许二次加工(如着色和密封)的高度有序的多孔结构。
可以通过将铝浸入酸性电解质浴(槽)中并使电流通过介质来实现阳极化。将阴极安装至阳极化槽的内部；将铝用作阳极，使得氧离子从电解质中释放以与位于正被阳极化的部分的表面处的铝原子结合。因此，阳极化是高度受控的氧化事件——自然发生现象的增强。可以通过使阳极化箔移动穿过合适(期望的)颜色的染料浴并且接着穿过密封剂浴来引入颜色。
在金属层上使用着色的阳极层提供了更大的灵活性和成本节省。由于金属比聚合物更致密并且不具有最小印刷厚度限制，因此使用印刷的阳极材料来代替聚合物材料克服了这些挑战。该组成和方法可以用于所有的交易和ID卡类型，包括非接触式、接触式和双接口智能卡。
根据本发明，可以通过下述方式进一步改变阳极化层的颜色和/或纹理：(a)给阳极化层染上单个颜色或多个颜色；或者(b)借助诸如丝网印刷、升华印刷或任何数字印刷系统的技术的印刷图形。可以通过诸如激光雕刻、机械雕刻、模切或压印的技术来进一步改变阳极化金属层。阳极化金属层可以作为整面材料(即，阳极化金属层延伸卡的全长和全宽)、补片、条纹或其他装饰性设计而用在卡上。阳极化金属可以被激光标记或以其他方式被雕刻成或标记成使得贱金属或贵金属可以以选择性的图案或防水涂层被电镀至阳极化表面。
根据本发明的一方面，使用至少一个阳极化的着色金属层和对可以被着色或可以未被着色的其他层进行选择性的改变来实现将颜色赋予给多层金属卡，以提供期望的艺术性和/功能性效果。
在装饰层是源自于植物物质(例如木材)的材料层的情况下，必须特别注意对装饰层进行处理以在将装饰层附接至金属基底之前和期间保持原始的(独特的)图案和纹理。本文中所使用的纹理指的是表面的视觉质量以及特别是触觉质量。这包括表面的感觉、触摸、外观和颗粒性。
同样地，在装饰层是源自于动物物质(例如皮革)的材料层的情况下，开发了特定的工艺来对装饰层进行处理以在将装饰层附接至金属基底之前和期间保持原始(独特)的图案和纹理。
另外，在装饰层是由源自于混合有激光反应性物质(例如，细碎碳)的各种集料粘合剂材料(例如，水泥、灰泥、环氧树脂)的材料构成的层的情况下，进行特定的布置以生产具有期望的颜色和纹理的顶表面的卡。
另外，具有选定的纹理和颜色的各种陶瓷材料可用于形成附接至金属基底的装饰层。
因此，薄装饰层可以是带纹理材料的单板层，所述带纹理材料可以是天然的和/或非金属性质的并且被制备和处理成为卡表面提供独特的和/或选定的纹理。
体现本发明的卡包括薄装饰层和金属、涂覆有陶瓷的金属、涂覆有陶瓷的聚合物或实心陶瓷材料的厚芯层。此外，卡可以包括多种不同的聚合物层。此外，体现本发明的金属卡可以包括集成电路芯片和天线以能够实现卡与读卡器之间的信号的RF(射频)传输。这些卡是还能够用作接触式卡和/或双接口(接触式和/或非接触式)的“智能”卡。
此外，体现本发明的卡可以包括袋状部，该袋状部形成在卡的顶表面中以能够将一个或更多个装饰层布置于其中。
附图说明
在未按比例绘制的附图中，相同附图标记指示相同的部件；并且
图1是根据本发明的、着色层被组合以形成具有受控着色的金属卡的截面图；
图1A是示出了去除了图1中所示的卡的顶层的部分以表现不同颜色的截面图；
图1B是示出了去除了图1中所示的卡的两个顶层的部分以表现更多颜色截面图；
图2是体现本发明的用于形成具有金属层和聚合物层的卡的选定层的截面图；
图3是体现本发明的具有着色层和金属层以及聚合物层的双接口智能卡的截面图；
图4是图3中所示的类型的卡的各层和部件(除了粘合层被省略以外)的分解图；
图5是包括附接至阳极化铝箔层的热固性聚合物层的可压印层的卡的截面图；
图5A是示出了图5中所示的类型的表面压印的卡的截面图；
图6是根据本发明的具有用以形成卡的四个着色层的卡的俯视图；
图6A是图6中所示的卡的截面图；
图6B是示出了阳极化铝层14可以形成为具有多个颜色层级的截面图；
图7是以图7A至图7E示出了根据本发明的用以形成具有天然木材单板的金属卡的工艺步骤中的一些工艺步骤的截面图；
图8是以图8A至图8D示出了根据本发明的用以形成具有水泥单板的金属卡的工艺步骤中的一些工艺步骤的截面图；
图9是以图9A至图9E示出了根据本发明的用以形成具有天然皮革单板的金属卡的工艺步骤中的一些工艺步骤的截面图；
图10A是形成在金属基底的顶表面中的袋状部的俯视图；
图10B是示出了附接至图10A的袋状部的装饰层的截面图；
图10C是示出了附接至金属基底的底表面的附加层的截面图；
图10D是其中形成有袋状部以将装饰层定位于其中的金属基底的俯视等距图，该装饰层可以例如是在如图7A、图8A或图9A中所示的阳极化金属层或任何单板层；
图10E是图10D的卡具有插入在袋状部中并附接至金属基底的装饰层的俯视等距图；
图11是示出了附接至金属基底的顶表面和底表面的装饰层的高度简化的截面图；
图11A至图11C是示出了附接至金属基底的顶表面和底表面的装饰层可以不同的截面图；
图11D是示出了附接至金属基底的顶表面和底表面的陶瓷层和装饰层的截面图；
图11E是具有陶瓷装饰层的金属卡的截面图，其中，向陶瓷装饰层施加激光源以改变卡的外观和纹理；
图11F是示出了根据本发明的附接至金属基底的顶表面和底表面的一类薄装饰层(阳极化铝)的截面图；
图12是具有附接至装饰层的底面的任选的聚合物层的卡的截面图；
图12A和图12B是附接至聚合物层的下侧或阳极化铝箔的下侧的签名板和磁条的仰视图；
图13A是根据本发明的具有附接至金属基底的着色的阳极化铝箔的卡的截面图；
图13B是示出了用于形成根据本发明的卡工艺步骤中的一些工艺步骤的视图；
图13C是示出了在图13A中的阳极化铝层中图案的形成的截面图；
图13D是示出了用贵金属对形成在图13A中的阳极化铝层中的图案进行电镀的结果的截面图；
图14是具有陶瓷芯和装饰层的卡的截面图；
图14A是形成在陶瓷芯层中的袋状部的等距俯视图；以及
图14B是附接至图14A的袋状部的装饰层的等距俯视图。
具体实施方案
具有至少一个阳极化层的金属卡
图1示出了具有多个不同着色层的基于金属的交易卡10的一个实施方案。在图1中，卡10包括覆盖在阳极化铝箔层14上的顶部着色硬涂层12。硬涂层12可以通过任何已知或合适的方式(例如，通过粘结、喷涂并固化、经由粘合剂或载体层附接或者从载体片转移)附接至阳极化层14。层14经由粘合层15附接至基础金属层16。层12和层14设计成具有选定的颜色，所述选定的颜色用于为卡10提供不同的着色外观和装饰外观。层12和层14的颜色可以与基础金属层16的颜色组合以为卡提供更大范围的颜色及装饰图案。
在卡的制造中，硬涂层12的厚度通常为2微米至50微米，铝箔层14的厚度可以在0.0005英寸至0.014英寸的范围内，金属层16的厚度可以在0.005英寸至0.032英寸的范围内。应当指出的是，层12是任选的并且层14主要旨在提供装饰(着色)功能。
层12提供耐刮擦表面并且还可以提供着色层。硬涂层12可以由纳米颗粒形成，例如为硅酸盐纳米颗粒、氧化锌纳米颗粒、二氧化硅晶体纳米颗粒或具有合适载体(如，溶剂、水基、或可UV固化的丙烯酸类、乙烯类、氨酯等)的任意其他合适的纳米颗粒。硬涂层可以通过涂覆技术(如，喷涂、凹版印刷、逆转辊、直接辊、狭缝涂覆)来施加。
硬涂层12可以借助于特定的载体层而被施加至卡或者被施加至用于形成卡的子组合件。特定载体使待附接至该特定载体层的释放层和硬涂层能够形成子组合件，该子组合件随后可以附接并转移至另一子组合件以形成载体层和释放层可以被去除的中间组合件，留下硬涂层作为卡的顶层和/或底层。硬涂层可以是透明的或者被着色的。通过将颜料或染料添加至粘合层或者混合有硬涂层载色剂自身来将颜色添加至硬涂层。
第二层14包括着色的阳极金属层，该着色的阳极金属层被示出为经由粘合层15附接至基础金属层16。层14还可以结合并层合至下面的层16。阳极化金属层14被示出为铝的阳极化金属层。然而，阳极化层14可以是钛、锌、铌、钽或能够被阳极化的任何其他金属。根据本发明，可以通过下述方式进一步改变阳极化层：(a)给阳极化层染上单个颜色或多个颜色；或者(b)通过借助诸如丝网印刷、升华印刷或任何数字印刷系统的技术的印刷图形。可以通过如激光雕刻、机械雕刻、模切或压印的技术进一步改变阳极化金属层。阳极化金属层可以作为整面材料(即，延伸卡的全长和全宽)、作为补片、条纹或其他装饰性设计被用在卡上。
将着色的阳极层14而非聚合物层用到着色的金属层16上提供了更大的灵活性并节省成本。由于金属比聚合物更致密并且没有最小印刷厚度限制，使用印刷的阳极材料来代替聚合物材料以克服在使用聚合物时存在的挑战。该组成和方法可以用于所有的交易和ID卡类型，包括非接触式、接触式和双接口智能卡。
在体现本发明的卡中使用的基础金属层或基底金属层16可以是任何合适的金属，如，不锈钢、青铜、铜、钛或给予卡以大部分其本体(结构)和重量的任意合金。
可以使用热、压力和/或UV固化来以一个或更多个层合步骤对层12、14、15和16进行组合。图1A和图1B示出了多层金属交易卡的构型，其中，基本上卡的整个本体是金属的并且其颜色可以被控制。签名板和磁条(未示出)可以(直接地或者经由聚合物层间接地)附接至图1、图1A和图1B中所示的金属层15的下侧以形成完整的交易卡。
图1、图1A和图1B中示出了用于向卡10施加激光束的激光器101。激光器101的功率水平由功率控制器103控制。对激光器的功率水平进行控制使得能够制造其颜色可以改变和控制的卡。激光器可用于对硬涂层12和阳极化层14的选定部分进行烧蚀。此外，激光器可以用于通过控制(改变)激光器的功率水平和偏振来改变基础金属层16的颜色(例如，这可以被称为一种类型的衍射激光器)。以此方式，每个卡的颜色和纹理均可以被控制和改变。
图1A示出了可以通过对顶层12进行选择性的激光烧蚀或者雕刻从而允许使第二层14显露来产生期望的颜色对比。这可以通过离散的、优化的激光器参数或雕刻技术来实现。
图1B示出了可以使用第二组参数来去除阳极层14的选定部分，从而示出下面的基础金属16。这允许在可以包括基础金属表面(finish)本身的金属卡上的多色渐变。这种美学外观在市场上是非常期望的。
应当指出的是，在图中仅示出了单个阳极化层。然而，还可以使用多于一个(即，多个)的合适的阳极化金属层。例如，由于每片铝有一个阳极化层，因此可以包括多个铝层。
混合型金属-聚合物卡
图2是包括图1中所示的着色层的卡10的截面图，并且卡10包括聚合物层18，聚合物层18通过粘合层17附接至金属层16的下侧。包括层12、14、15、16、17和18的该组合件可以被层合以产生包括金属层和至少一个聚合物层的组合的“混合”卡。聚合物层18可以由任何合适的材料(例如，PVC、PC、PET等)构成。聚合物层18可以包括磁条和签名板。替代性地，可以在卡已经与片材(在所述片材上形成多个卡)分离之后，随后添加磁条和签名板。
无线卡、接触式卡或双接口卡
图3是具有体现本发明的着色层的混合型双接口金属智能卡的截面图，图4是图3中所示这类卡的层和部件(除了粘合层已经被省略之外)的分解图。图3和图4示出了体现本发明的具有选定的纹理和颜色的卡可以被制成为包括使每张卡均制成为“智能”卡所需的所有部件。如图3和图4中所示，“智能”卡被制成包括集成电路模块109，集成电路模块109包括集成电路(IC)110(半导体处理器芯片或微芯片)和用于RF(无线/无接触)传输的模块天线112。模块109及其IC 110被设计成与读取器(未示出)接口。模块109及其IC 110还可以包括沿着卡的表面并且延伸至卡的周缘以与读取器接触的触点(116、118)。模块109及其IC110可以用作非接触(无线)系统的一部分和/或用作直接接触系统和/或双接口(接触和/或非接触)系统的一部分。在图3中，卡10包括经由粘合层19附接至金属层16下侧的铁氧体层20。在铁氧体层20与聚合物层18之间设置有层22，在层22上或层22中形成有增益天线。铁氧体层20被引入以防止金属层18使输入RF信号和输出RF信号减弱，从而使得能够在读卡器(未示出)与芯片110之间进行RF传输。存在穿过卡的顶层的切口以使模块109配合穿过。聚合物层18可以包括磁条和签名板或者可以将附加层24附接至层18以提供这些功能。通过添加着色的硬涂层12和阳极化金属层14，形成的如图3和图4中所示的“智能”双接口金属混合型卡可以被制成为具有期望的颜色和纹理特性并且还可以用作任何普通的混合型智能卡或金属卡。
图5和图5A是与图2中所示的卡类似的卡的截面图，但是图5和图5A中的卡另外还包括在阳极化铝膜层14的顶部上形成的可压印共聚物层24(在图中被标示为聚酯层)。可以通过将层12、24、14、16和18组装并借助于粘结和/或使用粘合层15、17、23使这些层附接而形成如图5中所示的卡10，接着可以借助于压印和层合板55a、55b对该组合件进行层合以及压印以产生如图5A中所示的位于顶层上的压印图像或者在其他顶层24和14中(层12是任选的并且可能并非用在所有卡上)产生压印图像。图5和图5A因此示出了如何通过压印来控制和改变卡的颜色和纹理。
替代性地，可压印层24可以是随后附接的可固化聚合物与粘合剂的层。硬涂层12可以在压印步骤之前或之后被布置在可压印层上。在进行层合期间，压印板55a可以用于将期望的图像压印到共聚酯层24中(层24可以是任何可压印的聚合物)并且还可以对位于共聚酯层24下方的阳极化金属层14进行压印。共聚酯层24(以及硬涂层)提供了耐刮擦层并且压印提供了工业所需的触觉部件。换言之，压印表面可以为卡提供纹理感。硬涂层12在聚酯的顶部提供额外的保护并且其载体提供从压印板的释放。
图6是金属交易卡的俯视图并且图6A是金属交易卡的截面图，通过该金属交易卡可以表现四种不同的颜色和多种图形及纹理特征。通过示例的方式，顶层12可以是黑色硬涂层，黑色硬涂层可以提供比PVD更耐刮擦且较不昂贵的背景。附接至层12的阳极化铝第二层14可以着色成粉色。附接至层14的第三金属层16着色成灰色。附接至层16的通常为薄塑料(但也可以是金属层)的第四层161着色成银色。激光源101可以用于产生带纹理且受控着色的卡。第一组激光装置将硬涂层12的选定部分去除从而使下面的阳极化层显露。该阳极化层在该实施例中为粉色并且可以用于文本或图形。第二激光装置将粉色的阳极化铝层14的一部分去除以产生金属层18的灰色特征。第三激光装置将灰色金属层的一部分去除以产生层161的银色特征。可以通过将每个层部分地去除来产生中间渐变。这开启了先前不可能实现的在金属交易卡上实施各种艺术和纹理的可能性。
图6B示出了阳极化层14可以形成为包含许多不同颜色的子层(141、142、143、144)。换言之，层14是多色层。在阳极化工艺期间，可以将不同的颜色引入至铝层的不同子区段(子层)。可以通过向下进行激光照射穿过层14的不同子层以表现不同的着色层来表现不同的颜色。代替激光照射，可以通过机械雕刻或其他材料去除手段来表现不同的颜色。附加层还可以是单独的或者与金属层组合的着色硬涂层。
如上所述，可以首先通过将选定的聚合物层与金属层组装并且使聚合物层与金属层粘结地或粘附地附接而形成如图1、图2、图3、图5和图6中所示的体现本发明的卡。通常在50PSIA至500PSIA的有效压力下、在200华氏度至500华氏度的温度范围内对各个层进行层合。典型地，使用第一组优化的激光器或机械雕刻参数将着色的转印硬涂层(例如层12)去除，从而显示下面的着色的阳极化层。接着，使用第二组优化的激光器或机械雕刻参数将着色的阳极化层(14)的部分去除，从而使下面的金属显露。在图6和图6A的情况下，可以使用第三组优化的激光器或机械雕刻参数来使另一着色层(161)显露。还可以穿过阳极化金属至卡的通常为不锈钢的主体来对各个层进行机械雕刻。作为制造卡的最后一个步骤，将卡切割成一定尺寸并且完成最终加工，如热冲压。
阳极化铝层因此用作薄装饰层(见图11中的DLa、DLb)。根据本发明的一个方面，薄装饰层包括至少一个阳极化金属层以为卡添加颜色和/或纹理。卡还可以包括不同颜色的附加层，所述不同颜色的附加层可与阳极化金属层一起组装以及层合以形成多层卡。卡可以被加工(例如，通过激光处理)以产生具有不同颜色和纹理的卡。受控变化的激光功率装置(或任何类似的功能器件)可以应用于多层卡以将不同层的选定部分去除，从而改变所显示的颜色和图案以及卡的纹理。
在制造体现本发明的卡时，出于商业和美学原因，生产具有某种纹理和颜色的金属卡并且保持该纹理和颜色已经变得重要。如上文所讨论的及如上文所示，体现本发明的金属卡可以形成为包括具有在金属层16之上的装饰层(例如，层14或图11中的DLa)的芯金属层16。替代性地，可以在芯金属层16的之上和之下、或者仅在芯金属层的之下形成有装饰层(例如，图11中的DLa、DLb)。
具有木材单板的卡
图7示出了具有薄装饰层的“带纹理”的金属卡的制造，该薄装饰层被选择成设置在卡的顶表面上的实际木材层。应当指出的是，“木材”的使用仅作为实施例并且意在包括源自于具有与木材的特性类似的特性的(活的)植物的任意材料。木材层(或任何类似材料)的使用由于其具有独特的性质而在美学上是重要的。也就是说，实际木条的颗粒(grain)和外观实际上是不可以进行复制的并且表现出高层次的个性化。然而，在保持用于形成卡的实际木材层的纹理和外观方面存在显著的问题。这些问题在根据本发明的卡的制造中被克服。
参照图7，可以使用下面的工序或步骤：
1.如图7A中所示，选择木质素含量低的天然木材单板层700。使用木质素含量低的木材层使得通过用于形成卡的各种层合及加工步骤而更容易保持木材层的外观。
2.对具有顶表面701和底表面703的木材层700进行预处理，如图7B中所示。
a.打磨木材层700的背表面703直到木材层具有期望的厚度为止。木材单板和所有其他单板的范围可以为0.001英寸至0.014英寸。
b.向木材层700的顶表面701施加油膜711如亚麻籽油；油层711确保木材层中所包含的水分和木材层的整体外观在木材层经受层合时得以保持。已发现，施加薄油膜(例如，亚麻籽油的薄油膜)在于层合过程中保持木材层处于良好状态方面是非常重要的。油用更高沸点的材料取代了木材结构中的水。
3.如图7C中所示，形成组合件750，组合件750包括通过粘合剂15a附接至金属基底16的经处理的木材层700。粘合层15a可以包括酸改性的聚烯烃或者可以是任何合适的粘合剂。通常，层700的厚度会在0.001英寸与0.014英寸之间并且金属层16的厚度会在0.005英寸与0.032英寸之间。
4.如图7D中所示，使用压板75a和75b来对组合件750进行层合。
5.应当指出的是，压板75a和/或75b还可以包括压印板(未示出)以使得组合件750能够同时被压印和层合。
6.如图7E中所示，对木材层700进行倒角以便切去(直角边缘或拐角)从而形成对称的斜边缘并且使卡的边缘磨损或剥离的问题最小化。具有水泥单板的卡
图8示出了具有薄装饰层的“带纹理的”金属卡的制造，该薄装饰层被选择为是集料粘合剂材料的单板层800。集料粘合剂材料可以是例如与如细碎碳或商售的激光添加剂的激光反应性物质混合的水泥、灰泥、环氧树脂以及胶。在图8A中，层800被示出为是混合有碳材料的水泥层。然而，如上面所指出的，水泥可以是所提及的材料中的另一材料。水泥层的使用提供了独特的触感。然而，在制造具有特定纹理和颜色的卡以及保持纹理并提供具有高水平对比度的图像时存在很大的问题。在根据本发明的这些卡的制造中克服了这些问题。
参照图8，以下过程或步骤可以用于处理集料粘合剂材料(例如，水泥)和增强处理的卡的颜色对比度。
1.如图8A中所示，由水泥混合物形成水泥层800，已将碳材料(例如，炭黑)添加在该水泥混合物中以产生浅灰色的水泥层800。
2.对层800的顶表面和/或底表面(801、803)进行研磨以产生具有期望厚度的层，期望的厚度通常在0.001英寸与0.010英寸之间。
3.如图8B中所示，使用激光装置101来对水泥层进行激光处理以产生期望的图案(区域804)。激光器101使选定区域中的碳颗粒气化，以产生与灰色背景形成对比的白色图案。
4.激光处理的水泥层800随后可以经由合适的粘合层15b附接至金属基底16，以形成如图8C中所示的组合件850。
5.替代上述步骤3，首先可以将未被激光处理的水泥层800附接至金属基底16，然后进行激光处理。
6.图8D示出了可以使用混合有碳颗粒的环氧树脂材料来形成层800a。层800a可以直接附接至金属基底16。层800a可以在层800a附接至金属基底16之前或在附接之后进行激光处理步骤。环氧树脂材料的使用消除了对额外的粘合层的需要并且在环氧树脂层800a与下面的金属基底16之间提供了非常强的结合，所述金属基底16可以例如是钢或任何其他合适的金属。
具有皮革单板的卡
图9示出了具有薄装饰层的“带纹理的”金属卡的制造，该薄装饰层被选择为位于卡的顶表面上的真实皮革单板层。指出的是，可以使用任何类似的源自动物的材料进行替代。如在“天然”或“真实”的木材层的情况下，使用真实皮革层是重要的，这是由于真实皮革层具有许多独特的性质。也就是说，由真实皮革层表现的外观的颗粒和丰富度以及图案实际上不可复制，并且表现出高层次的个性化。然而，在保持用于形成卡的“天然”皮革层的纹理和外观方面存在很大的问题。在根据本发明的卡的制造中克服了这些问题。
参照图9，可以使用以下过程或步骤来形成卡：
1.如图9A中所示，进行选择步骤。也就是说，选择在其顶表面901上具有天然独特图案的天然皮革层900。
2.随后，进行皮革加工或处理以用于准备皮革层900的背面903，使得皮革层具有期望的厚度，并且底表面适于接纳粘合剂。典型的厚度将在0.003英寸至0.014英寸的范围内。然而其可以做得更薄和更厚。
3.随后，进行如图9B中所示的压印步骤。将期望的图案压印在第一(1st)皮革层900的顶表面901上。
4.随后，用于将皮革层900层合至下面的金属基底16的非常新颖的特征部还使得能够产生镜像压印图案。具有重要意义的是，用于将压印皮革层900固定至下面的金属基底16的层合过程保留了皮革900层的所有精细特征部以及压印图案。这是以如下方式来实现的。形成如图9C中所示的组合件910，组合件910包括：
a.经由粘合层15c附接至金属基底层16的压印的第一皮革层900；以及
b.示出位于压印皮革层900与压板75a之间的具有面向压印表面901的第一皮革层900的顶表面的坯料(未压印)皮革层902(即皮革层)。层902可以类似于层900或可以是任何类似的皮革状材料。层902被选定为具有与层900的纹理相同或相似的纹理。
5.如图9D中所示，组合件910经历了层合步骤。由于层900和层902(和适当的层合压力)的适当选择，层合过程保持第一皮革层900中压印的特征部和图案完整，从而产生如图9E中所示的组合件或子组合件950。
6.同时，压印图案转移(作为镜像)至第二皮革层902的顶表面911，所述顶表面911随后可以用于压印随后的皮革层或类似层，如图9E中所示。这是重要的，由于“未压印”的皮革层(例如，902)成为用于制造下一系列卡的模板；从而产生连续生产。
具有用于装饰层/补片的袋状部的卡
单板层的边缘可能会受到磨损和剥离。避免这个问题的一种方法是对单板层的边缘进行倒角，如图7E中所示。另一种方法是在金属卡的顶表面中形成袋状部981，如图10A中所示。图10A是具有切口981以在卡的顶表面中形成袋状部的卡的俯视图。袋状部可以使用任何已知的技术形成。边缘d1和d2可以在0.01英寸至1.125英寸的范围内，并且可以是不平坦的或形成艺术图案。图10B是示出了阳极化铝层14或任何单板层(例如，700、800、900)可以经由合适的粘合剂15c附接至从芯金属层16切出的卡的袋状部981的顶内表面的横截面图。这种布置是优雅的并且保护了阳极化层或单板层的边缘免于磨损、磨破或剥离。
图10C示出了聚合物层、铝或陶瓷层可以附接至金属基底的下面。
图10D是形成有袋状部981的金属层16的等距俯视图。出于说明的目的，示出的袋状部不是对称定位的。袋状部981可以制作成具有规则或不规则边界的卡表面的小部件或大部件。图10E示出了任何装饰层(DL)可以附接至袋状部981或形成在袋状部981内。这包括阳极化铝层、上述的各种单板层以及任何其他装饰的单板板层或物质。这包括作为示例的目前商售的被称为施华洛世奇元素晶体织物(Swarovski Elements Crystal Fabric)的产品。这种材料包括完全被数以百万计的微小切割和圆形的晶体覆盖的载体材料。它是弹性的、抗撕裂的并且非常轻的。载体材料以低温胶为特色使得可以通过低温加热而被应用至各种表面。这种胶可以用更强的粘合剂来代替以用于更严酷的环境。
在本发明的其他实施方案中，具有几乎任何形状的非常有限面积的小袋状部(例如，卡的表面区域的小部件)可以形成在卡中以用于包含任何装饰材料。
上面作为说明。通常，根据本发明，已经示出了下述各种方法和装置：所述各种方法和装置用于处理薄的阳极化金属层和/或选定的薄单板层以用于附接至厚金属基底，从而生产具有期望的颜色和纹理特性的卡。
体现本发明的金属卡可以如图11中所示的那样形成为包括在金属层上方具有装饰层(DLa)并且在金属层下方具有装饰层(DLb)的芯金属层16。装饰层DLa和DLb中的每一者均可以是：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；或(f)晶体织物材料层。也就是说，一个装饰层(例如，DLa)可以是上面的标识为a至f的层中的任一层，并且另一个装饰层(例如，DLb)可以类似于DLa或者是与标识为a至f的层不同的层。
在图11A中，金属基底16的一侧(图中的顶表面)经由粘合剂15c附接有皮革层900，并且金属基底的另一侧(图中的底表面)附接有阳极化铝层14。在该图中(以及在下面的图11B和图11C中)，金属基底的顶部附接有一种类型的薄装饰层(例如，皮革)并且金属基底的底表面附接有不同的薄装饰层(例如，阳极化铝)。
在图11B中，金属基底16的一面(顶表面)经由粘合剂15c附接有皮革层900，并且金属基底的另一面(底表面)附接有陶瓷单板层990。
在图11C中，金属基底16的一面(顶表面)经由粘合剂15附接有阳极化铝箔14a，并且金属基底的另一面(底表面)附接有陶瓷单板层990。陶瓷层990被示出为附接有签名板123和磁条125。
图11B和图11C示出了装饰性单板层可以是陶瓷材料层990。陶瓷材料具有非常期望的特性，这是由于陶瓷材料可以被制成为具有几乎任意的颜色并且可以在不使用粘合剂的情况下附接(粘结)至金属基底。陶瓷材料层可以被直接应用(例如，喷涂)至金属基底16，并且随后在金属基底16上烘烤或固化至金属基底16。此外，图11B和图11C示出了装饰层中的一个装饰层可以是一种类型的单板层(皮革、阳极化铝)，另一个装饰层可以是不同类型(例如，陶瓷)。
图11D示出了金属基底16可以具有附接至金属基底16的顶表面的装饰层DLa和陶瓷层990a以及附接至金属基底16的底表面的装饰层DLb和陶瓷层990。由于可用于装饰层和陶瓷层的不同颜色和纹理的范围宽，因此，卡可以被制成具有非常宽范围的着色和纹理。
图11E示出了激光源101，所述激光源101可以用于对附接至金属基底16的顶表面的装饰性陶瓷层990a进行激光雕刻，所述金属基底16具有附接至层16的底表面的相同或不同的装饰层DLb。陶瓷层990a还可以利用机械或化学雕刻、喷墨印刷、激光标记和本领域已知的其他方法进行修改，从而提供了期望的艺术效果。
图11F示出了具有附接至其顶表面的阳极化铝箔14a和附接至其底表面的阳极化铝箔14b的金属基底16。箔14a和14b可以具有不同的颜色、厚度和形状。
图12是金属卡的截面图，其示出了与图11F的结构类似的结构。该卡具有经由粘合剂15附接至金属基底16的一个侧部(图中的顶表面)阳极化铝层14a和经由粘合剂17附接至金属基底的另一个侧部(图中的底表面)的另一阳极化铝层14b。阳极化铝层14a和14b是附接至金属层16的装饰层。聚合物层121示出为附接至层14b的底侧。如图12A中所示，层121可以是透明的聚合物层以使得可以显示并观察到层14b的着色特征和装饰特征。签名板123和磁条25形成在层121的表面上。
层121的使用是任选的。如图12B中所示，卡的底层可以是层14b(即，不使用聚合物层)。在特定实施方案中，本申请的申请人使用热固性类型的粘合剂来将签名板123和磁条125直接附接至阳极化的铝层14b。
图13A示出了体现本发明的卡的着色特征和装饰特征。在图13A中，顶部阳极化层14a具有例如被着色为蓝色的顶部区域141。区域141的厚度可以在小于0.1微米至大于5微米的范围内。(然而，应当理解的是，区域141的厚度具有宽的变化)。层14a经由粘合层15附接至芯金属基底16，芯金属基底16又经由粘合剂17附接至装饰层DLb，所述装饰层DLb可以是以上标识为(a)至(f)的任何类型的层。
如图13B中所示，在将图13A中所示的层组装之后(见框1041)，可以通过去除区域141中的阳极材料的选定部分来形成图案(见框1042)，从而留下下面的未着色的铝箔。也就是说，层14或14a的部分在区域141下方。可以借助于激光或通过任何其他合适的方式进行去除区域141中的材料。例如，如果使用激光器，则激光仅去除层141中的材料，直到通过区域141，露出层141的剩余部分。这在图13C中示出，所述图13C中示出了限于去除区域141中的蓝色着色材料的选定部分的图案。随后，可以利用诸如金或任何合适的金属之类的金属对经激光处理的组合件进行电镀工艺(见框1043)，从而将选定的金属电镀在形成于阳极区域141中的图案上或内部。形成的图案可以具有图13D所示的外观。可以对卡进行进一步加工(完成)，如框1044中所示，用以包括任何和所有附加的特征部，从而形成如上所述的所有类型的卡。
陶瓷卡
图14示出了卡10a可以形成有陶瓷芯131，所述陶瓷芯131可以设计成提供预定颜色。装饰层DLa可以附接至陶瓷芯的顶侧和/或另一个装饰层DLb可以附接至芯层的底侧。装饰层DLa可以与装饰层DLb相同；但它们不必相同。图14A示出了可以在陶瓷层内形成袋状部981，以用于在袋状部981中放置如图14B中所示的装饰层(DL)。装饰层可以是上述类型中的任何层或任何其他合适的材料。陶瓷材料是由金属和非金属的化合物制成的无机非金属材料。陶瓷材料可以是结晶的或部分结晶的。陶瓷材料通过热作用和随后的冷却而形成。陶瓷材料趋于为坚固的、坚硬的、脆的、化学惰性的非热电导体。
出于与期望使用金属卡的原因类似的原因而期望使用陶瓷卡。在现代交易卡市场中，通常期望获得可被销售给富裕市场的“高端”感觉、外观或触觉特征。这些交易卡可以用作借记卡、信用卡或预付卡。作为这种高端感觉的一部分，通常是需要卡比标准塑料卡重，以及增加了耐久性的卡体也是需要的。为了实现这些期望的效果，本文描述了利用陶瓷部件的几种卡构造，包括呈下述形式的示例性实施方案：固态陶瓷卡、包括陶瓷插入件的卡、以及利用陶瓷涂层的卡。
实心陶瓷卡可以利用注射成型形成其期望的形状，随后烧结以形成标准尺寸的卡的标称尺寸：3.37”×2.125”×0.03”(不过不限于任何特定尺寸)。可以在注射成型过程中形成袋状部以允许插入诸如磁条、接触件或双接口芯片模块、用于双接口卡的增益天线、全息图、签名板或品牌之类的功能特征部。陶瓷卡体还可以由更大块的陶瓷形成并且加工至期望的尺寸。也可以3D印刷生产陶瓷部件。在优选实施方案中，陶瓷可以包括烧结的二氧化锆，但也可以并非限制性地包括以下氧化物中的一者或更多者：氧化铝、氧化铍、二氧化铈、神经酰胺(ceramide)、碳化物、硼化物、氮化物或硅化物。
实心陶瓷卡向现有的高端金属卡提供了功能性优点，这些优点在于实心陶瓷卡不必被显著地机加工、不产生静电放电、并且不干扰用于非接触式交易的RF辐射。在美学上，可以通过向陶瓷化合物中添加颜料以获得多种颜色的固态陶瓷卡，并且可以通过激光标记、添加诸如激光签名特征部或装饰设计特征部之类的期望的特征部对固态陶瓷卡进行进一步改变。诸如通孔、窗口或微文本之类的安全元件也可以经由激光、机械或化学雕刻或通过本领域已知的任何方法添加。
如图11B、图11C、图11D和图11E中所示，还可以提供包括包含有金属和陶瓷的金属陶瓷复合材料的交易卡。在一个实施方案中，陶瓷插入件可以放置在金属和金属塑料卡中以形成独特的特征部并增加卡上的可用颜色特征、纹理特征和激光特征，同时保持金属卡的大部分重量。例如，这样的插入件可以通过在芯中研磨袋状部、将粘合剂放置在袋状部中、以及将陶瓷插入件粘合在袋状部中来附接。在另一实施方案中，陶瓷插入件和研磨的袋状部可以分别构造成使得将陶瓷插入件以压配合的方式保持就位。在又一实施方案中，芯可以具有设置在其边缘中的一个或更多个螺纹孔，使得芯用作框架，其中，设定螺纹孔中所固定的螺钉以将陶瓷插入件保持在框架内。然而，陶瓷插入件至芯的附接不限于任何特定的方法。
还可以提供具有双层和单层陶瓷涂层的金属芯卡(见图11B、图11C、图11D和图11E)。金属芯可以包括0.024”至0.030”(但不限于任何特定厚度)的固态金属，诸如但不限于包括下述金属：黄铜、钢、镍、钯、银、金、铂、铝或本领域已知的任何其他合适的金属或金属合金。金属芯还可以包括复合结构，诸如包含粘结至厚度为0.001”至0.029”(但不限于任何特定厚度)的第二金属的0.001”至0.029”厚度(但不限于任何特定厚度)的第一金属的芯、或者构成期望的厚度的卡的任何多个层。这种复合材料可以期望用于可以显示陶瓷何时被激光标记的特定重量或颜色。利用复合金属还可以提高成本效率。具有单层和双层陶瓷涂层的金属陶瓷复合卡可以实现期望的制造成本效果、重量效果和艺术效果。
在一个示例性实施方案中，0.02”厚的金属芯(如钢)可以在一侧上结合有0.007”厚的PVC层，其中，金属芯的未结合表面上具有陶瓷涂层。陶瓷可以应用为喷涂涂层，随后以热、通风或UV的方式固化。在固化之后，涂层通常为0.001”至0.003”厚，这取决于涂层的期望的外观。这些涂层可以以多种颜色生产。通常，涂层包括包含有二氧化锆、二硅化铝和悬浮在挥发性有机载体溶液中的可固化树脂结合剂的陶瓷微粒，诸如由NIC Industries,Inc制造或代表的陶瓷涂层。一旦喷涂并固化，则涂层为卡提供独特的颜色和纹理，以及极其耐久光洁度，通常达到几千个泰伯(Taber)的磨损循环。陶瓷涂层可以用机械雕刻或化学雕刻、喷墨印刷、激光标记和本领域已知的其他方法修改，以提供期望的艺术效果，诸如包括诸如例如在图11E中所示卡上的设计。交易卡的磁条、签名板、品牌、全息图和其他功能特征部可以直接应用于陶瓷表面(见图11C中的123、125)，或者可以例如通过机械雕刻或激光雕刻来形成袋状部(见图10C)，以允许这种特征部粘结至金属芯。
因此，用于生产具有金属芯的示例性陶瓷卡的示例性方法可以包括以下步骤：
1.提供金属芯板。(提供金属芯的任选步骤可以包括将诸如铝箔之类的金属箔层合到内部子芯的一个或更多个表面，其中子芯可以包括任何材料，但通常是金属或塑料)。
2.向金属芯添加固定件，例如，在执行接下来的步骤时添加用于将板保持就位的固定孔和固定件。
3.形成例如用于保持与RFID芯片结合使用的增益天线的诸如袋状部的表面特征部，所述表面特征部可以设置在陶瓷层下面。另外，可以提供芯中的袋状部，从而最终导致陶瓷涂层中的凹陷，稍后的部件(如，RFID芯片)可以在加工结束时附接到所述凹陷中，从而在最终产品中提供光滑表面。
4.对芯施加表面抛光(喷丸处理、滚磨、刷涂等)。
5.在一侧或两侧涂覆陶瓷。
6.对具有设计部或其他表面特征部的激光标记涂覆有陶瓷的金属板进行任何期望的其他机械、化学或激光修改以便于随后附接其他部件。例如，可以加工任何袋状部或凹陷的边缘，以用于更好地配合在随后的步骤中添加的特征部，或者稍后施加粘合剂的区域可以被粗糙化以获得更好的粘合。
7.如利用CNC(计算机数字控制)机将板切割成卡坯料。
8.将功能特征部和安全特征部(磁条、芯片、全息图等)应用于单个卡坯料。如上所述，这样的特征部可以装配在过程中较早形成的袋状部中或粘合地附接至已经粗糙化的区域。然而，磁条优选直接施加在陶瓷涂层上，这是由于应用到尽可能平坦和平整的表面上的益处。
在传统地包括复合塑料或聚碳酸酯的识别卡市场中，陶瓷提供了新的可能性，以增加卡的寿命并使伪造卡更具挑战性。可以将经着色的且透明的陶瓷涂层应用于塑料芯以形成如通过ISO标准挠性和磨损测试所测试的显著地更耐用的材料。此外，这些材料更难以伪造并且允许独特的激光标记性能以及在陶瓷中包含独特的磷光体，所述磷光体可以向上或向下移动入射光以形成作为ID的部分的独特的光“水印”。
Claims (57)
1.一种用于制作具有给定外观的卡的方法，所述方法包括下述步骤：
选择薄装饰层并且对所述薄装饰层进行加工以使所述薄装饰层具有在0.0005英寸至0.014英寸范围内的厚度；其中，所述薄装饰层是下述中之一：(a)阳极化金属层；b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；(d)集料粘合剂材料的单板层，例如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层；以及
选择厚芯层以用于形成所述卡的本体，所述厚芯层具有在0.005英寸至0.032英寸的范围内的厚度以及彼此大致平行的第一表面和第二表面；所述厚芯层是：(a)金属的厚芯层、或(b)涂覆有陶瓷的金属、或(c)涂覆有陶瓷的聚合物、或(d)实心陶瓷材料；以及
将所述薄装饰层附接至所述厚芯层的所述第一表面。
2.根据权利要求1所述的方法，其中，附接所述薄层和所述厚层的步骤包括对所述薄层和所述厚层进行层合；其中，所述薄装饰层是设计成具有给定颜色的阳极化铝层，所述方法还包括对所述阳极化铝层施加激光源以用于改变所述卡的颜色外观和纹理的步骤。
3.根据权利要求1所述的方法，其中，附接所述薄层和所述厚层的步骤包括对所述薄层和所述厚层进行层合；其中，所述薄装饰层是具有给定颜色的阳极化铝层；所述方法还包括在所述阳极化铝层上形成硬涂层的步骤；所述方法还包括向所述硬涂层和所述阳极化铝层施加激光源以用于改变所述卡的颜色和触感中的至少一者的步骤。
4.根据权利要求3所述的方法，其中，所述硬涂层设计成具有不同于所述阳极化铝的颜色的颜色。
5.根据权利要求2所述的方法，还包括附接至所述厚芯层的所述第二表面的聚合物层。
6.根据权利要求2所述的方法，还包括附接至所述厚芯层的所述第二表面的聚合物层和位于所述卡内的集成电路模块，所述集成电路模块用于实现以下中的至少之一：(a)所述卡与外部读卡器之间的无线射频(RF)传输、和(b)所述卡与接触式读取器之间的接触式读取。
7.根据权利要求2所述的方法，还包括附接至所述阳极化铝层的可压印的聚合物层，所述方法还包括对所述聚合物层和所述阳极化铝层进行压印的步骤。
8.根据权利要求1所述的方法，其中，所述厚芯层是厚金属层，其中，所述薄装饰层是设计成具有给定颜色的阳极化铝层；其中，所述厚金属层被设计成具有不同的颜色；还包括具有预选定的颜色的至少一个附加层；所述方法还包括向所述阳极化铝层、所述厚金属层和所述附加层施加激光源以用于改变所述卡的颜色和感觉中的至少一者的步骤。
9.根据权利要求1所述的方法，其中，所述源自植物的材料的单板层是木质素含量低的天然木材的层，其中，对所述木材单板层进行的加工包括：(a)打磨所述木材层的背表面直到所述木材层具有0.001英寸与0.015英寸之间的厚度为止；和(b)向所述木材层施加油膜以在所述木材层经历层合时保持所述木材层的外观。
10.根据权利要求9所述的方法，还包括对所述木材层的外边缘进行倒角以防止所述木材层的磨损或剥离的步骤。
11.根据权利要求1所述的方法，其中，所述源自动物的材料的单板层是具有顶表面和底表面的天然皮革层，其中，对所述皮革单板层进行的加工包括对所述皮革层的所述底表面进行处理以使得所述皮革层的厚度在0.001英寸与0.015英寸之间并且使得所述皮革层的所述底表面适于接纳粘合剂。
12.根据权利要求11所述的方法，还包括下述步骤：
对所述皮革层的所述顶表面进行压印；以及
形成包括所述皮革层的第一组合件，所述皮革层的所述底表面附接至所述厚芯层的所述第一表面。
13.根据权利要求12所述的方法，其中，所述厚芯层是厚金属层，其中，经压印的所述皮革层是第一皮革层，所述方法还包括下述步骤：
形成第二组合件：包括对具有顶表面和底表面的第二皮革层进行定位，使得所述第二皮革层的所述顶表面面向所述第一组合件的经压印的所述第一皮革层的顶表面；以及
对所述第一皮革层和所述第二皮革层以及所述厚金属层进行层合，由此将所述第一皮革层的压印图案转移至所述第二皮革层并且对第一组合件的部件进行层合。
14.根据权利要求1所述的方法，其中，所述集料粘合剂材料的单板层是混合有激光反应性物质的水泥或环氧树脂的层；所述方法还包括向混合有碳颗粒的所述水泥或环氧树脂的层施加激光源以使所述碳颗粒气化并产生具有高对比度的图案的步骤。
15.根据权利要求1所述的方法，其中，将所述薄装饰层附接至厚芯层的所述步骤包括在所述厚芯层的表面内形成袋状部以及将所述薄装饰层中之一牢固地附接在所述袋状部内的步骤。
16.根据权利要求15所述的方法，其中，所述袋状部的深度被制成为大致等于所述装饰层的厚度。
17.根据权利要求1所述的方法，其中，所述薄装饰层是阳极化金属层，所述方法还包括给所述阳极化金属层染上多种颜色的步骤。
18.根据权利要求1所述的方法，其中，所述薄装饰层是阳极化金属层，所述方法还包括通过下述中之一来改变所述阳极化层的步骤：通过诸如丝网印刷、升华印刷、任何数字印刷系统、激光雕刻、机械雕刻、模切或压印的技术的印刷图形。
19.根据权利要求1所述的方法，其中，所述薄装饰层是阳极化金属层，其中，所述阳极化金属层选择性地以如下方式沿着所述卡的表面延伸：(a)所述卡的全长和全宽，(b)作为补片，(c)作为条纹，(d)作为装饰性设计。
20.根据权利要求1所述的方法，还包括将所述薄装饰层附接至所述厚金属层的所述第二表面的步骤。
21.根据权利要求20所述的方法，其中，附接至所述厚金属层的所述第二表面的所述薄装饰层包括下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层。
22.根据权利要求1所述的方法，其中，所述厚芯层是厚金属层，其中，所述薄装饰层是陶瓷材料层，其中，对所述薄装饰层进行选择和加工的步骤包括将所述陶瓷层施加到所述厚金属层上并且使所述陶瓷层粘结至所述厚金属层。
23.根据权利要求1所述的方法，其中，所述薄装饰层是薄阳极化金属层，所述薄阳极化金属层具有延伸至所述薄金属层内给定深度的预定着色区域；所述方法还包括下述步骤：(a)根据设计图案去除所述着色区域的选定部分至所述给定深度；和(b)用颜色不同于所述预定着色区域的电镀金属对所述薄阳极化金属层进行电镀，以用于产生表现所述电镀金属和所述预定着色区域的颜色的图案。
24.根据权利要求23所述的方法，其中，所述薄阳极化金属层是具有顶部子层区域的薄铝层，所述顶部子层区域被染成具有所述预定颜色，其中，去除所述着色区域的选定部分的步骤包括使用激光装置来使所述阳极化铝层的选定部分露出，其中，所述电镀金属为贵金属如金。
25.一种具有正面和背面的卡，所述卡包括：
厚芯层，所述厚芯层的厚度在0.005英寸至0.032英寸的范围内；所述厚芯层形成所述卡的主体并且具有预定颜色，所述厚芯层具有大致彼此平行延伸的第一表面和第二表面；以及
薄装饰层，所述薄装饰层附接至所述厚芯层的所述第一表面以用于为所述卡提供颜色和纹理中的至少之一；所述薄装饰层的厚度在0.0005英寸至0.03英寸的范围内；所述薄装饰层是下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；和(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层。
26.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述薄装饰层是阳极化铝层，所述阳极化铝层设计成具有给定颜色并且具有形成在所述阳极化层内以表现阳极化铝和下面的厚金属层的颜色的图案，所述卡具有对应于所形成的图案的独特的纹理。
27.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述薄装饰层是具有给定颜色的阳极化金属层；其中，在所述阳极化铝层上形成有硬涂层；在所述硬涂层和所述阳极化铝层内形成有图案以产生表现所述硬涂层的颜色、所述阳极化层的颜色和所述厚金属层的颜色的图案。
28.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述薄装饰层是具有给定颜色的阳极化铝层；其中，在所述阳极化铝层上形成有经着色的硬涂层；其中，附加层附接至厚金属，其具有不同于所述卡的其他层的颜色；其中，在所述硬涂层和所述阳极化铝层以及所述厚金属层内形成有图案以产生表现所述硬涂层的颜色、所述阳极化层的颜色、所述厚金属层的颜色以及所述附加层的颜色的图案。
29.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，所述卡还包括附接至所述厚芯层的所述第二表面的聚合物层。
30.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，所述卡还包括：(a)附接至所述厚金属层的聚合物层、和(b)集成电路模块，所述集成电路模块位于所述卡内以用于实现下述中的至少之一：(i)所述卡与外部读卡器之间的无线射频(RF)传输、和(ii)所述卡与接触式读取器之间的接触式读取。
31.根据权利要求25所述的卡，其中，所述厚芯层是金属层，所述卡还包括附接至所述阳极化铝层的可压印的聚合物层；其中，在所述聚合物层内压印有图案以用于产生能够被感知的相应图案。
32.根据权利要求25所述的卡，其中，所述厚芯层是金属层，其中，所述薄装饰层是设计成具有给定颜色的阳极化铝层；其中，所述厚金属层设计成具有不同的颜色；所述卡还包括具有预选定的颜色的至少一个附加层；其中，所述层的选定部分通过激光照射、机加工或化学蚀刻中的一者来去除以产生其外观随所述层的颜色而变化的卡，所述卡的所述纹理随所形成的图案而变化。
33.根据权利要求25所述的卡，其中，所述源自植物的材料的单板层是木质素含量低的实际木材层；所述木材层具有在0.001英寸与0.010英寸之间的厚度；其中，所述实际木材层具有顶表面，所述顶表面由沿着所述顶表面设置的油膜保护。
34.根据权利要求33所述的卡，其中，所述木材层的外边缘经倒角以防止所述木材层的磨损或剥离。
35.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述源自动物的材料的单板层是具有顶表面和底表面的实际皮革层，所述顶表面具有与实际皮革相关联的独特图案；所述皮革单板层具有0.001英寸与0.020英寸之间的厚度；如此处理的所述皮革层的所述底表面适于接纳粘合剂；其中，所述皮革层的所述顶表面经压印并且所述皮革层的所述底表面经由粘合层附接至所述厚金属层。
36.根据权利要求25所述的卡，其中，所述集料粘合剂材料的单板层是混合有激光反应性物质的水泥或环氧树脂的层；其中，由于所述碳颗粒的气化而在所述单板层中形成有图案。
37.根据权利要求25所述的卡，其中，所述阳极化金属层是多色金属层。
38.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，附接至所述厚金属层的所述第一表面的所述薄装饰层是第一薄装饰层；其中，所述厚金属层的所述第二表面附接有第二薄装饰层。
39.根据权利要求38所述的卡，其中，所述第二薄装饰层是下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；和(d)集料粘合剂材料的单板层，例如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层。
40.根据权利要求38所述的卡，其中，附接至所述厚金属层的所述第一表面的所述薄装饰层不同于附接至所述厚金属层的所述第二表面的薄装饰层。
41.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，在所述厚金属层的所述第一表面中形成有袋状部，其中，所述厚金属层的所述袋状部内附接有薄装饰层。
42.根据权利要求41所述的卡，其中，附接至所述厚金属层的所述袋状部内的所述薄装饰层是晶体织物材料层。
43.根据权利要求38所述的卡，其中，所述第二薄装饰层是阳极化金属箔，所述卡还包括附接至所述第二薄装饰层的信号板和磁条。
44.根据权利要求38所述的卡，其中，所述第二薄装饰层是阳极化金属箔，所述卡还包括附接至所述第二薄装饰层的聚合物层以及附接至所述聚合物层的信号板和磁条。
45.根据权利要求25所述的卡，其中，所述薄装饰层是薄阳极化金属层，所述薄阳极化金属层具有延伸至所述薄阳极化金属层内给定深度的预定着色区域；其中，所述着色区域的选定部分根据设计图案被去除至所述给定深度；在已去除的所述选定区域内电镀有颜色不同于所述预定着色区域的特定金属，以用于产生表现所述特定金属的颜色和所述预定着色区域的颜色的图案。
46.根据权利要求45所述的卡，其中，所述薄阳极化金属层是具有顶部子层区域的薄铝层，所述顶部子层区域被染成具有所述预定颜色，其中，所述特定金属是贵金属如金。
47.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述厚金属层的所述第一表面附接有陶瓷层，所述陶瓷层附接有不同于陶瓷层的薄装饰层。
48.根据权利要求25所述的卡，其中，所述厚芯层是厚金属层，其中，所述厚金属层的所述第一表面附接有第一陶瓷层，以及所述厚金属层的所述第二表面附接有第二陶瓷层。
49.根据权利要求25所述的卡，其中，所述厚芯层是厚陶瓷层。
50.一种金属卡，包括：
厚金属层，所述厚金属层的厚度在0.005英寸至0.035英寸的范围内；所述厚金属层形成所述卡的主体并具有预定颜色；所述厚金属层具有顶表面和底表面；
袋状部，所述袋状部形成在所述厚金属层的所述顶表面内，所述袋状部的深度在所述厚金属层的表面下方延伸0.003英寸至0.030英寸；和
边界，所述边界围绕所述金属层的外周；以及
薄装饰层，所述薄装饰层附接至形成在所述厚金属层的所述顶表面内的所述袋状部。
51.根据权利要求50所述的金属卡，其中，所述薄装饰层的厚度在0.005英寸至0.030英寸的范围内；其中，所述薄装饰层是下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层。
52.根据权利要求51所述的卡，其中，所述阳极化金属层是铝、钛、锌、铌、钽或者能够被阳极化的任意其他金属中之一。
53.根据权利要求51所述的卡，其中，所述单板层是木材、皮革、陶瓷、晶体织物材料、水泥或环氧树脂中之一。
54.一种制作卡的方法，所述方法包括下述步骤：
选择具有大致平行的顶表面和底表面的厚金属层；所述厚金属层的厚度在0.005英寸至0.033英寸的范围内；
在所述厚金属层的所述顶表面中形成袋状部；所述袋状部的深度在所述厚金属层的所述顶表面下方延伸0.003英寸至0.030英寸，并且形成围绕所述厚金属层的外周的边界；以及
将薄装饰层附接至形成在所述厚金属层的所述顶表面内的所述袋状部，以用于为所述卡提供颜色和纹理中的至少之一。
55.根据权利要求54所述的金属卡，其中，所述薄装饰层的厚度在0.003英寸至0.030英寸的范围内；其中，所述薄装饰层是下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；以及(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂。
56.一种制作卡的方法，所述方法包括下述步骤：
选择具有顶表面和底表面的第一类似皮革的材料的层；
将图案压印在所述第一类似皮革的材料的所述顶表面上；
选择具有顶表面和底表面的第二类似皮革的材料的层；
形成组合件：包括将所述第二类似皮革的层的所述顶表面放置到经压印的第一层的所述顶表面上使得所述第一层覆盖金属基底并且附接至所述金属基底；
对所述组合件进行层合以使经压印的第一层与所述金属基底层叠以用于形成卡或卡的子组合件，同时还对所述第二类似皮革的层的所述顶表面进行压印。
57.一种具有正面和背面的卡，所述卡包括：
厚陶瓷层，所述厚陶瓷层的厚度在0.005英寸至0.032英寸的范围内；所述厚陶瓷层形成所述卡的主体并且具有预定颜色，所述厚金属层具有大致彼此平行延伸的第一表面和第二表面；以及
薄装饰层，所述薄装饰层附接至所述厚陶瓷层的所述第一表面以用于为所述卡提供颜色和纹理中的至少之一；所述薄装饰层的厚度在0.0005英寸至0.014英寸的范围内；所述薄装饰层是下述中之一：(a)阳极化金属层；(b)源自植物的材料的单板层，如木材；(c)源自动物的材料的单板层，如皮革；和(d)集料粘合剂材料的单板层，如混合有激光反应性物质的水泥或环氧树脂；(e)陶瓷层；以及(f)晶体织物材料层。
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| US20170098151A1 (en) | 2017-04-06 |
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| US11853829B2 (en) | 2023-12-26 |
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| CN106462782B (zh) | 2020-04-03 |
| EP3146476A4 (en) | 2017-12-13 |
| BR112016027213A2 (pt) | 2021-06-08 |
| SG10201801283SA (en) | 2018-04-27 |
| AU2015264126A1 (en) | 2016-12-01 |
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| JP6680767B2 (ja) | 2020-04-15 |
| US10867233B2 (en) | 2020-12-15 |
| BR112016027213B1 (pt) | 2022-11-01 |
| NZ726408A (en) | 2018-09-28 |
| JP2020015321A (ja) | 2020-01-30 |
| JP2017525601A (ja) | 2017-09-07 |
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