WO2014201335A1

WO2014201335A1 - Card with polymeric layer and topcoat layer

Info

Publication number: WO2014201335A1
Application number: PCT/US2014/042278
Authority: WO
Inventors: Matthew John STRUCK
Original assignee: Datacard Corporation
Priority date: 2013-06-14
Filing date: 2014-06-13
Publication date: 2014-12-18

Abstract

A technique is described that eliminates silvering on personalized plastic cards protected by a topcoat. A layer of polymeric material is applied to the card substrate and the printed personalization, such that the polymeric layer is disposed between the topcoat and the card substrate. The polymeric layer provides a number of benefits, including eliminating silvering by improving topcoat adhesion, improving abrasion resistance of the topcoat, enhancing plasticizer resistance, and permitting a lowering of topcoat lamination temperatures while maintaining durability.

Description

The technical disclosure herein relates to personalized plastic cards, such as identification cards, driver's licenses, financial cards such as credit and debit cards, employee badges, and the like.

Background

The use of personalized plastic cards is widespread, Many plastic cards are personalized by printing on the card substrate, followed by application of a protecti ve layer such as a laminate or topcoat over the printing to protect the printing and extend the life of the card.

With reference to Figure 1, an example of a known type of plastic card 2 is illustrated. The card 2 includes a card substrate 4, printing 6 applied to an upper surface of the substrate, and a topcoat layer 8 that is applied over the printing 6 and adhered using adhesive 10. On some personalized plastic cards, areas of poor adhesion between the protective topcoat layer 8 and the card substrate 4 can manifest themselves as visually unacceptable silvering and/or bubbles on the resulting card 2. Poor adhesion can also impact durability.

Summary

A technique is described herein that eliminates silvering on personalized plastic cards protected by a topcoat. In one embodiment, a layer of polymeric material is printed on the card substrate and the printed personalization, such that the printed polymeric layer is disposed between the topcoat and the card substrate. In other embodiments, the polymeric layer can be deposited on to the card by a lamination process. The polymeric layer provides a number of benefits, including eliminating silvering by improving topcoat adhesion, improving abrasion resistance of the topcoat, enhancing plasticizer resistance, and permitting a lowering of topcoat lamination temperatures while maintaining durability,

In one embodiment, a personalized plastic card is provided that includes a card substrate, personalization printed on a surface of the card substrate, a polymeric layer disposed on the surface over the printed personalization, and a protective topcoat layer disposed on the polymeric layer.

In one embodiment, the polymeric layer can have a thickness from about 0.5 μηι to about 5.0 μηι.

In one embodiment, the card further comprises an adhesive layer between the polymeric layer and the topcoat layer, and the topcoat layer and the adhesive layer have a combined thickness from about 2.0 μηι to about 15 μηι.

In another embodiment, the card can have warpage less than about 0.055 inches, preferably less than about 0.053 inches, and more preferably less than about 0.050 inches. Card warp was measured in accordance with Section 5.1 of ISO/IEC 10373-1 :2005, which is hereby incorporated by reference herein.

In an oth er embodiment, a m ethod is provided including th e steps of printing personalization on the surface of a card substrate, applying a polymeric layer on the surface of the card substrate over the printed personalization, and applying a protective topcoat layer onto the polymeric layer. In some embodiments, the polymeric layer can be applied by a print ribbon and the topcoat layer can be applied by lamination,

In some embodiments, both the topcoat layer and/or the polymeric layer can be laminates composed of multiple layers.

Figure 1 illustrates a prior art multi-layer, laminated plastic card.

Figure 2 is an end view of a multi-layer, laminated plastic card described herein with a polymeric material disposed between the card substrate and the topcoat.

Figure 3 illustrates an exam le of a plastic identification card that is constructed as described herein. Detailed Description

As described in further detail bel ow, a layer of polymeric material is printed or otherwise deposited by lamination or any other suitable means, onto a surface of a card substrate after the surface has been printed with the appropriate personalization, such as a photograph of the intended card holder, the card holder's name, background images, logo(s), and the like. A protective topcoat is then applied over the polymeric layer to form the plastic card.

The techniques described herein can be applied to any types of plastic cards where one wishes to improve the adhesion between a protective topcoat and a card substrate. Examples of the types of plastic cards that can benefit from the techniques described herein include, but are not limited to, identification cards, driver's licenses, financial cards such as credit and debit cards, employee badges, and the like.

With reference to Figure 2, an end view of a multi-layer, laminated plastic card 20 that incorporates the techniques described herein is illustrated. The card 20 includes a card substrate 22, printing 24 applied to an upper surface of the substrate 22, a layer of polymeric material 26, and a topcoat layer 28 that is applied over the polymeric layer 26 and adhered using an adhesive layer 30. The thickness of the various layers, both individually and relative to one another, is greatly exaggerated in order to better illustrate the card construction.

The substra te 22 can be formed of one or more layers of polymeric materials, such as polyvinyl chloride (PVC), composite laminations of varying ratios of PVC/ Polyethylene terephthalate (PET) and copolymers thereof, PVC/^'poiycarbonate (PC), polyesters, polycarbonates, ABS, polyolefins, polystyrene and combinations thereof. In some embodiments, the substrate 22 can comprise from about 30 percent by weight to about 50 percent by weight PVC and from about 50 percent by weight to about 70 percent by weight PET. In other embodiments, the substrate 22 can comprise from about 15 percent by weight to about 25 percent by weight PVC and from about 75 percent by weight to about 85 percent by weight PET.

The printing 24 is appiied using known techniques, for example, a direct-to-card process such as dye sublimation or pigment mass-transfer printing. The printing 24 is illustrated as a continuous layer, although the printing 24 may or may not be continuous and may or may not have a continuous thickness, In one example, where printing is applied, the printing can have a thickness of between about 0-4.0 μηι. The printing 24 can be text (variable or non-variable), images (variable or non-variable), and the like (collecti vely referred to herein for sake of convenience as personalization) that is typically printed on personalized plastic cards.

Variable information or "personalization" varies from card to card and is personal to or associated with the intended hol der of the card. Examples of variable information can include, but are not limited to, a photograph of the intended card hol der, the card holder's name, the card holder's address, signature, an account number assigned to the card holder, and the like.

Non-variable information or "personalization" does not vary from card to card, but is ins tead the same from card to card. Examples of non-variable information can include, but are not limited to, background images, logo(s), and the like.

In one example, the printing 24 is applied using a thermal printhead and a suitable thermal print ribbon such as a YMCK print ribbon.

In other embodiments, the printing 24 can be applied through a re-transfer printing process known in the art where printing is applied to a transfer layer which is then laminated or otherwise secured onto the substrate 22. If a re-transfer process is used, the polymeric layer 26 can also be transferred with or separately from the transfer layer containing the printing.

The topcoat layer 28 can be made of resin such as ure thane, vinyl, acrylic, other abrasion resistant chemistry, or combinations thereof. In one embodiment, the topcoat layer 28 and the adhesive layer 30 can have a combined thickness of between about 2.0 to about 15.0 μ,ηι, preferably between about 7.0 to about 13.0 μιη, The topcoat layer 28 can be air dried, heat set, UV radiation cured, or laminated using an adhesive. In some embodiments, the topcoat layer 28 can be a continuous coating that covers the entire surface of the substrate (i.e., edge-to-edge coating). In one possible embodiment, the topcoat layer can be laminated as a continuous edge-to-edge layer over the card substrate and the polymeric layer. The topcoat layer 28 can be applied by a lamination process at a temperature between about 155°C to about 200 °C. In one embodiment, the topcoat layer is applied via lamination at a temperature less than about 1 85 °C. Lamination speed can be between about 0.33 inches/second to about 1.65 inches/second.

The adhesive layer 30, which can be separately applied or formed integrally as part of the topcoat layer 28, can be any heat-sensitive adhesive that is activated by reaching a pre-determined temperature, for example during a lamination process via a heated lamination roller. Suitable adhesives include, for example, polyester resins, vinyl resins, acrylic resins, epoxy resins, vinyl chloride-vinyl acetate copolymer resins, polyamide resins, polyester-urethane resins, and combinations thereof. In some embodiments, a tie coat layer may be applied between the topcoat 28 and the adhesive layer 30 and/or between various layers of the topcoat 28 to increase interfaciai adhesion. The tie coat can be any chemical composition that aids in the interfaciai adhesion.

The topcoat layer 28 and the adhesive layer 30 can be as described in U.S. Patents 5,781,316 and 7,179,518, both of which are incorporated herein by reference in their entirety.

In some embodiment, an enibossable coating layer can be disposed between the protective topcoat layer 28 and the adhesive layer 30, The enibossable coating layer can be formed from, for example, urethane, nitro-cellulose, or combinations thereof. The enibossable coating layer can include at least one optically variable image (e.g., hologram), in an embodiment, the enibossable coating layer can further include a reflective metal or high refractive layer to enhance holographic effect of the optically variable image.

The polymeric layer 26 can be any suitable polymeric material that reduces or eliminates silvering and/or promotes adhesion between the substrate 22 and the topcoat layer 28. Suitable polymeric layers can include, for example, resins layers such as vinyl resins, acrylic resins, polyester resins, polyurethane resins, epoxy resins, polyamide resins, polyimide resins and combinations thereof. The polymeric layer 26 can have a thickness of, for example, between about 0.5 to about 5.0 μηι. In one embodiment, the polymeric layer is transferred onto the substrate 22 via a thermal printhead. In some embodiments, the polymeric layer 26 can comprise from about 15 percent by weight to about 100 percent by weight vinyl resin, while in other

embodiments the polymeric layer 26 can comprise from about 20 percent by weight to about 80 percent by weight vinyl resin. In further embodiments, the polymeric layer 26 can comprise from about 25 percent by weight to about 60 percent by weight vinyl resin. In other embodiments, the polymeric layer can comprise from about 15 percent by weight to about 100 percent by weight acrylic resin and in still further embodiments the polymeric layer can comprise from about 20 percent by weight to about 80 percent by weight acrylic resin. Sub-ranges within these explicit ranges are contemplated and are within the scope of this disclosure.

The polymeric layer 26 can have a similar chemistry as the adhesive layer 30. For example, if the adhesi ve layer 30 includes an acrylic resin, the polymeric layer 26 can include an acrylic resin. While not wanting to be limited by theory, it is believed that including the polymeric layer 26 with similar chemistr as the adhesive layer 30 promotes adhesion between the topcoat 28 and the substrate 22, which in turn reduces and/or eliminates silvering.

In some embodiments, the polymeric layer 26 can be applied as a continuous coating to the entire surface of the substrate (edge-to-edge coating), while in other embodiments the polymeric layer 26 can be applied as a continuous coating such that one or more gaps exist between an edge of the substrate 22 and an edge of the polymeric layer 26. In some embodiments, the layer of polymeric material is applied to only a portion of the card substrate .

In another embodiment, the same thermal printhead is used to produce both the printing 24 and the polymeric layer 26, For example, the polymeric material for forming the polymeric layer 26 can be provided from a YMCKT printer ribbon (where T designates one or more panels that includes a suitable polymeric material) or a YMCKF- KT printer ribbon (where F designates one or more panels that include a suitable polymeric material and fluorescent compounds/additives). Suitable YMCKT and YMCKF -KT printer ribbons are available from DataCard Corporation of Mmnetonka, Minnesota. The polymeric layer 26 improves the adhesion between the topcoat layer 28 and the substrate 22 to help eliminate silvering, improves the abrasion resistance of the topcoat layer 28, enhances plasticizer resistance of the topcoat layer 28, and permits a reduction in the temperature used to laminate the topcoat layer 28 while maintaining the durability of the topcoat layer 28.

In one embodiment, a card produced as described herein has less than 0.055 inches of warp as measured in accordance with Section 5.1 of ISO/IEC 10373-1:2005,

Figure 3 is a top view of a plastic card 38 that is constructed as described herein. The card 38 includes the layers described with respect to the card construction in Figure 2, with the layers being formed and applied as described above, in this example, the card 38 is an identification card, credit card or other form of plastic card tha t has variable card holder information provided thereon. For example, the card 38 has an upper, generally planar face 38 that is disposed opposite of a rear, generally planar face (not visible in Figure 3). Various variable card holder data is visible on the upper face 38 including an image 40 of the head and face of the intended card holder, other card holder data 42 such as the person's name, national identification number, birthdate and citizenship, and a signature 44 of the card holder. The specific variable data illustrated in Figure 3 is an example only, and other variable data, as well as non-variable data, can be provided either in addition to or separate from the variable data 40, 42, 44.

Test Results

The following table illustrates example test results that have been achieved. The term T-panel in the table below refers to a polymeric layer 26 formed from a YMCKT printer ribbon The term F-panel in the table below refers to a polymeric layer 26 formed from a YMCKF-KT ribbon.

Lamination 185° C/ 0.53 in/sec 185°a 0.53 in/sec 175° C/ 0.5.3 in/sec 175°a 0.5.3 in/sec (Temp/Speed)

Taber Abrasion I ,000 1 ,750 1,500 1,500

(cycles to

breakthrough)

Topcoat Adhesion 3.5 4 4 4

(5 = best)

Plasticizer 10 9.75 10 10

Resistance

24 Hours

(10 - best)

Plasticizer 9.5 9.75 10 10

Resistance

48 Hours

( 10 - best)

Card Warpage 0.066 0.056 0.049 0.045

(inches)

The embodiments disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the claimed invention is indicated by any appended claims rather than by the foregoing description, and ail changes which come within the meaning and range of equi valency of the claims are intended to be embraced therein.

Claims

1 . A personalized plastic card, comprising:

a plastic card substrate;

personalization printed on a surface of the card substrate;

a polymeric layer disposed on the surface of the card substrate over the printed personalization;

a protective topcoat layer disposed on the polymeric layer.

2. The personalized plastic card of claim 1 , wherein the polymeric layer has a thickness between about 0.5 μηι to about 5.0 μηι.

3. The personalized plastic card of claim 1, further comprising an adhesive layer between the polymeric layer and the protective topcoat layer.

4. The personalized plastic card of claim 1, wherein the polymeric layer comprises a resin selected from the group consisting of vinyl resins, acrylic resins, polyurethane resins, polyester resins, epoxy resins, polyamide resins, polyimide resins and combinations thereof.

5. The personalized plastic card of claim 1, wherein the card has less than 0.055 inches of warp as measured in accordance with Section 5.1 of ISO/IEC 10373- 1 :2005.

6. The personalized plastic card of claim 3, wherein the topcoat layer and adhesive layer have a combined thickness between about 2.0 μιη to about 15.0 μηι, preferably between about 7.0 μ,ιη to about 13.0 μηι,

7. The personalized plastic card of claim 1, wherein the topcoat iayer comprises a resin selected from the group consisting of urethane, vinyl, acrylic, and combinations thereof.

8. The personalized plastic card of claim 3, further comprising an embossabie coating layer between the protective topcoat layer and the adhesive layer, the embossable coating layer comprising at least one optically variable image.

9. The personalized plastic card of claim 8, wherein the embossable coating layer further comprises a reflective metal or high refractive layer to enhance holographic effect of the optically variable image, and the embossabie coating layer comprises urethane, nitro-cellulose, or combinations thereof.

10. The personalized plastic card of claim 3, wherein the adhesi ve layer comprises an acrylic resin and the polymeric layer comprises at least 15 percent by weight acrylic resin.

11. The personal ized plastic card of claim 3, wherein the adhesi ve layer comprises a vinyl resin and the polymeric layer comprises at least 15 percent by weight vinyl resin.

12. A method, comprising:

printing personalization on a surface of a card substrate;

applying a layer of polymeric material on the surface of the card substrate over the printed personalization; and

applying a protective topcoat layer onto the polymeric layer.

13. The method of claim 12, wherein the topcoat iayer is applied via lamination at a temperature less than about 185 °C.

14. The method of claim 12, wherein the topcoat layer is applied via lamination at a temperature between about 155 °C and about 200 °C and the lamination speed is between about 0.33 inches/second and about 1.65 inches/second.

15. The method of claim 12, wherein the layer of polymeric material is applied by printing the polymeric layer from a printer ribbon.

16. The method of claim 12, wherein the layer of polymeric material is applied such that at least one gap exists between an edge of the card substrate and an edge of the polymeric material.

17. The method of claim 12, wherein the layer of polymeric material is applied to only a portion of the card substrate.