# US 8,672,232 B2 · Combination card of metal and plastic

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- Number: US 8,672,232 B2
- Document ID: US8672232B2
- Status: Granted
- Kind: B2
- Application number: 13/135,139
- Filed: 2011-06-27
- Published: 2012-12-27
- Granted: 2014-03-18
- Earliest claimed: 2011-06-27
- Assignees: CompoSecure, LLC
- Applicants: John Herslow
- Inventors: John Herslow
- Web page: https://patentgrep.com/patent/US8672232B2

## CPC

- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 37/06: characterised by the heating method
- G06K 19/02: characterised by the selection of materials, e.g. to avoid wear during transport through the machine
- G06K 19/06196: {Constructional details}
- B32B 37/12: characterised by using adhesives
- B32B 37/142: {Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket}
- B32B 2309/02: Temperature
- B32B 2309/12: Pressure
- B32B 2311/00: Metals, their alloys or their compounds
- B32B 2323/04: Polyethylene
- B32B 2327/06: PVC, i.e. polyvinylchloride
- B32B 2333/08: Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
- B32B 2425/00: Cards, e.g. identity cards, credit cards
- B32B 2519/02: RFID tags
- Y10T 156/1041: Subsequent to lamination
- Y10T 428/24917: including metal layer
- Y10T 428/2495: Thickness [relative or absolute]
- Y10T 428/31681: Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
- Y10T 428/31699: Ester, halide or nitrile of addition polymer
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- G06K: GRAPHICAL DATA READING (image or video recognition or understanding G06V); PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A card formed in accordance with the invention includes a first assembly comprised of multiple plastic layers attached via an adhesive to a metal layer. The multiple plastic layers forming the first assembly are laminated under a first selected temperature and pressure conditions to preshrink the multiple plastic layers, stress relieve the first assembly and render the first assembly dimensionally stable. The laminated first assembly is then attached to a metal layer via an adhesive layer to form a second assembly which is then laminated at a temperature below the first selected temperature to form a card which is not subjected to warpage and delamination.

## Claims

### Claim 1

A method of making a card comprising the steps of:
forming a first assembly of a first predetermined thickness, said first assembly including at least two layers of plastic material;
firstly laminating the at least two layers of different plastic material at a first predetermined temperature and pressure for forming said first assembly; wherein said first lamination step comprises preshrinking the at least two layers of plastic material and reducing subsequent dimensional changes of the layers forming the first assembly;
secondly forming a second assembly including said first assembly and a metal layer with an adhesive layer between the first assembly and the metal layer; and
laminating the second assembly at a temperature which is lower than the first predetermined temperature.

### Claim 2 (depends on 1)

A method as claimed in claim 1, wherein the at least two layers of plastic material includes different plastic materials, wherein the first predetermined temperature is a temperature in excess of 300 degrees Fahrenheit; and wherein the laminating temperature of the second assembly is at a temperature of less than 300 degrees Fahrenheit.

### Claim 3 (depends on 1)

A method as claimed in claim 1, wherein the at least two layers of plastic material includes different plastic materials, and wherein the plastic layers may be selected from a polyvinyl chloride (PVC) material, a polyethylene terephthalate (PETG) material, a poly carbonate (PC) material or any like plastic material.

### Claim 4 (depends on 1)

A method as claimed in claim 1, wherein the metal layer may be formed from one of stainless steel, brass, copper, aluminum, or any appropriate metal material or any clad metal layer.

### Claim 5 (depends on 1)

A method as claimed in claim 1 wherein the thickness of the first assembly makes up substantially half of the card's thickness and the metal layer makes up substantially the other half of the card's thickness.

### Claim 6 (depends on 1)

A method as claimed in claim 1, wherein the outer surface of the first assembly includes at least one of a printed pattern, a magnetic stripe, a hologram, a contact chip and a signature panel.

### Claim 7 (depends on 1)

A method as claimed in claim 1, wherein the outer surface of the metal layer includes a pattern formed by at least one of etching, engraving, lasering, embossing or coining the outer surface of the metal layer.

### Claim 8 (depends on 1)

A method as claimed in claim 1, further including the placement of an RFID chip between selected layers of the plastic layers forming said first assembly prior to the lamination of the first assembly.

### Claim 9 (depends on 1)

A method as claimed in claim 1, wherein the first assembly includes a core layer with a first clear overlay plastic layer above the core layer and a second clear overlay plastic layer below the core layer.

### Claim 10

A method as claimed 1, further including the step of embossing the second assembly after it has been laminated for the purpose of personalizing the card.

### Claim 11

A card comprising:
a first assembly comprised of multiple plastic layers which wherein the multiple plastic layers have been laminated at a first temperature and pressure to preshrink the layers and reduce their subsequent dimensional changes; said first assembly having an inner surface and an outer surface;
the outer surface defining one of the top and bottom side of the card;
a layer of metal material and an adhesive layer;
the layer of metal material having an inner surface and an outer surface; the inner surface of the layer of metal material being attached to the inner surface of the first assembly via said adhesive layer, the combination of said first assembly, adhesive layer and the metal layer forming a second assembly which is laminated at a temperature which is less than the first temperature, and wherein the outer surface of the layer of metal material defines the other one of the top and bottom side of the card.

### Claim 12 (depends on 11)

The card as claim in claim 11, wherein said first assembly comprised of multiple plastic layers includes at least two different plastic materials, wherein the card has a given thickness; and wherein the first assembly has a thickness, which constitutes substantially one half of the card's thickness and wherein the thickness of the layer of metal constitutes substantially the other half of the card's thickness.

### Claim 13 (depends on 11)

The card as claim in claim 11, wherein the first assembly includes a core layer with a first clear overlay plastic layer above the core layer and a second clear overlay plastic layer below the core layer.

### Claim 14 (depends on 11)

The card as claim in claim 11, wherein the plastic layers may be selected from a polyvinyl chloride (PVC) material, a polyethylene terephthalate (PETG) material, a poly carbonate (PC) material or any like plastic material and wherein the metal layer may be formed from one of stainless steel, brass, copper, aluminum, or any appropriate metal material or any clad metal layer.

### Claim 15 (depends on 11)

The card as claim in claim 11, wherein the outer surface of the first assembly includes at least one of a printed pattern, a magnetic stripe, a hologram, a contact chip and a signature panel.

### Claim 16 (depends on 11)

The card as claimed in claim 11 wherein the outer surface of the metal layer includes a pattern formed by at least one of etching, engraving, lasering, embossing or coining the outer surface of the metal layer.

### Claim 17 (depends on 11)

The card as claimed in claim 11 further including the placement of an RFID chip between selected layers of the plastic layers forming said first assembly prior to the lamination of the first assembly.

### Claim 18 (depends on 11)

A card as claimed in claim 11, wherein the second assembly forms a metal-plastic card and wherein the card is embossed from the plastic side to form a pattern which extends from the plastic side and through to the metal side, whereby the embossed pattern causes a raised pattern on the metal side.