# US 10,769,515 B2 · Composite laminate assembly used to form plural individual cards and method of manufacturing the same

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- Number: US 10,769,515 B2
- Document ID: US10769515B2
- Status: Granted
- Kind: B2
- Application number: 15/890,766
- Filed: 2018-02-07
- Published: 2018-08-16
- Granted: 2020-09-08
- Earliest claimed: 2017-02-16
- Assignees: Illinois Tool Works Inc.
- Applicants: Illinois Tool Works Inc.
- Inventors: Daniel Szumski; Suwit John Sangkaratana; Roger D. Strasemeier
- Web page: https://patentgrep.com/patent/US10769515B2

## CPC

- G06K 19/07722: {the record carrier being multilayered, e.g. laminated sheets (flat articles in general, see B32B37/00)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/08: of synthetic resin
- B32B 15/082: comprising vinyl resins; comprising acrylic resins
- B32B 15/09: comprising polyesters
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 37/203: {One or more of the layers being plastic}
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 38/145: {Printing}
- B32B 2250/05: 5 or more layers
- B32B 2250/24: All layers being polymeric
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/205: Metallic coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2307/202: Conductive
- B32B 2307/204: Di-electric
- B32B 2307/206: Insulating
- B32B 2307/208: Magnetic, paramagnetic
- B32B 2307/416: Reflective
- B32B 2307/418: Refractive
- B32B 2307/732: Dimensional properties
- B32B 2307/75: Printability
- B32B 2425/00: Cards, e.g. identity cards, credit cards
- B32B 2519/02: RFID tags
- G06K: GRAPHICAL DATA READING (image or video recognition or understanding G06V); PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A laminated core stock sheet for use in a composite laminate assembly that is separated into individual cards is provided. The sheet includes a core substrate layer and an intermediate filmic layer coupled to the core substrate layer. The intermediate filmic layer includes a conductive material that provides a security, decorative, or functional feature of the cards. The core substrate layer and the intermediate filmic layer are coupled with another laminated core stock sheet to form the composite laminate assembly. The conductive material has a small thickness within the intermediate filmic layer such that the intermediate filmic layer prevents conduction of electrostatic discharge (ESD) through the intermediate filmic layer and outside of the individual cards.

## Claims

### Claim 1

A laminated core stock sheet for use in a composite laminate assembly configured for being separated into plural individual cards, the laminated core stock sheet comprising:
a core substrate layer; and
an intermediate filmic layer coupled to the core substrate layer, the intermediate filmic layer including a conductive material that provides at least one of a security feature, a decorative feature, or other functional feature of the individual cards, wherein the core substrate layer and the intermediate filmic layer are configured to be coupled with another laminated core stock sheet that may or may not include the intermediate filmic layer to form the composite laminate assembly configured for being separated into the individual cards,
wherein the conductive material has a small thickness within the intermediate filmic layer such that the intermediate filmic layer prevents conduction of electrostatic discharge (ESD) through the intermediate filmic layer and outside of the individual cards,
wherein the conductive material forms a layer that extends across the intermediate filmic layer, the layer of the conductive material extending continuously such that the layer of the conductive material is essentially devoid of visibly spaced-apart bodies of the conductive material.

### Claim 2 (depends on 1)

The laminated core stock sheet of claim 1, wherein the conductive material is formed from one or more of aluminum, zinc, gallium, indium, cadmium, copper, nickel, cobalt, iron, magnesium, platinum, tin, chromium, silver, rhodium, or palladium.

### Claim 3 (depends on 1)

The laminated core stock sheet of claim 1, wherein the intermediate filmic layer extends over all or substantially all of a planar surface area of the core substrate layer.

### Claim 4 (depends on 1)

The laminated core stock sheet of claim 1, wherein the intermediate filmic layer has one or more of a reflective mirror surface or a holographic effect.

### Claim 5 (depends on 1)

The laminated core stock sheet of claim 1, wherein the conductive material of the intermediate filmic layer is configured to permit electromagnetic waves that are wirelessly communicated with radio frequency identification (RFID) devices disposed inside the individual cards through the intermediate filmic layer.

### Claim 6 (depends on 5)

The laminated core stock sheet of claim 5, wherein the intermediate filmic layer is configured to not inhibit the electromagnetic waves having sub-gigahertz frequencies from passing through the intermediate filmic layer.

### Claim 7 (depends on 1)

The laminated core stock sheet of claim 1, wherein the conductive material of the intermediate filmic layer has an optical density of at least 0.25 but no greater than 4.0.

### Claim 8

A composite laminate assembly configured to be separated into plural individual cards, the assembly comprising:
a first laminated core stock sheet including a first core substrate layer and a first intermediate filmic layer coupled to the first core substrate layer, the first intermediate filmic layer including a conductive material that provides at least one of a security feature, a decorative feature, or other functional feature of the individual cards;
a second laminated core stock sheet including at least a second core substrate layer, wherein the first laminated core stock sheet and the second laminated core stock sheet are configured to be laminated together;
a first overlay layer configured to be coupled with the first laminated core stock sheet; and
a second overlay layer configured to be coupled with the second laminated core stock sheet such that the first and second laminated core stock sheets are disposed between the first overlay layer and the second overlay layer,
wherein the conductive material of the first intermediate filmic layer has a sufficiently small thickness to prevent conduction of electrostatic discharge (ESD) through the first intermediate filmic layer and outside of the individual cards,
wherein the conductive material forms a layer that extends across the first intermediate filmic layer, the layer of the conductive material extending continuously such that the layer of the conductive material is devoid of visibly spaced-apart bodies of the conductive material.

### Claim 9 (depends on 8)

The composite laminate assembly of claim 8, wherein the conductive material is formed from one or more of aluminum, zinc, gallium, indium, cadmium, copper, nickel, cobalt, iron, magnesium, platinum, tin, chromium, silver, rhodium, or palladium.

### Claim 10 (depends on 8)

The composite laminate assembly of claim 8, wherein the first intermediate filmic layer is buried beneath the first overlay layer.

### Claim 11 (depends on 8)

The composite laminate assembly of claim 8, wherein the first intermediate filmic layer extends between all or substantially all of planar surface areas of the first laminated core stock sheet and the first overlay layer.

### Claim 12 (depends on 8)

The composite laminate assembly of claim 8, wherein the first intermediate filmic layer has a reflective mirror surface.

### Claim 13 (depends on 8)

The composite laminate assembly of claim 8, further comprising a radio frequency identification (RFID) inlay layer disposed between the first laminated core stock sheet and the second laminated core stock sheet, the RFID inlay layer including one or more RFID devices.

### Claim 14 (depends on 13)

The composite laminate assembly of claim 13, wherein the conductive material of the first intermediate filmic layer permits electromagnetic waves communicated with the RFID device to wirelessly pass through the first intermediate filmic layer.

### Claim 15 (depends on 14)

The composite laminate assembly of claim 14, wherein the first intermediate filmic layer is configured to permit the electromagnetic waves having sub-gigahertz frequencies to pass through the first intermediate filmic layer.

### Claim 16 (depends on 14)

The composite laminate assembly of claim 14, wherein the conductive material of the first intermediate filmic layer has an optical density of at least 0.25 but no greater than 4.0.

### Claim 17 (depends on 8)

The composite laminate assembly of claim 8, wherein the second laminated core stock sheet also includes a second intermediate filmic layer coupled to the second core substrate layer, the second intermediate filmic layer including conductive material that also provides at least one of a security feature, a decorative feature, or other functional feature of the individual cards.

### Claim 18

A method comprising:
depositing a conductive material onto a continuous filmic web; and
coupling the filmic web with the conductive material to a core substrate layer to form a first laminated core stock sheet, wherein the first laminated core stock sheet is configured to be coupled with a second laminated core stock sheet that may or may not include the intermediate filmic layer to form a composite laminate assembly configured for being separated into individual cards, wherein the conductive material is deposited at a thickness that prevents conduction of electrostatic discharge (ESD) through the first intermediate filmic layer and outside of the individual cards through the filmic web,
wherein the conductive material is deposited at the thickness such that the conductive material has an optical density of at least 0.25 but no greater than 4.0.

### Claim 19 (depends on 1)

The laminated core stock sheet of claim 1, wherein the conductive material constitutes a thin layer.

### Claim 20 (depends on 19)

The laminated core stock sheet of claim 19, wherein the conductive material is configured to enable conduction of ESD through the intermediate filmic layer, if not for the small thickness.