Ink jet printers are known and provide a number of advantages in the printing process. For example, ink jet printers are capable of providing relatively high-density color output at an acceptable printing speed. Furthermore, such printers are relatively inexpensive. As a result, it is desirable to utilize such printers in the formation of identification cards.
Identification card substrates generally have polyvinyl chloride (PVC) or polyvinyl chloride/polyvinyl acetate (PVC/PVCAc) surfaces. These surfaces can be printed using a Dye Diffusion Thermal Transfer (DDTT) technology where dyes and/or resins are deposited at or near the surfaces of the card substrates. Images printed on the surfaces of these card substrates are susceptible to defacement due to abrasion, exposure, water and other environmental conditions. Accordingly, a protective material should be applied over the printed card surface to protect the printed image.
To provide protection to the printed image on the card substrate surface, overlays can be applied to the printed card surface. Thin film overlays can be used to provide edge-to-edge protection to a printed surface. Unfortunately, such thin overlays only provide limited protection to the printed card surface.
In the alternative, patch laminates can be applied to printed card surfaces to provide additional protection to DDTT images. Patches generally made of a polyester (PET) film and a thermal adhesive provide a bond between the polyester film and the card surface. Although patch laminates exhibit resilient protection for a printed card surface, patch laminates do not generally provide edge-to-edge protection to the printed card surface since they are formed slightly smaller than the card. Additionally, after lamination of a patch, card substrates can become warped along the outer edges of the identification card.
Ink-receptive films have been applied to card substrates to form an ink-receptive surface thereon.
Unfortunately, the above-described process of forming an ink-receptive card substrate using an ink-receptive film is problematic. The layers of adhesive, ink-receptive film, card member, and the laminate, result in a complex and expensive ink-receptive card substrate. Also, the backing layer of the ink-receptive film can potentially delaminate from the card member due to its exposed edges, thereby limiting the useful life span of the ink-receptive card substrate. Additionally, the image that is printed to the ink-receptive surface that is formed by the ink-receptive coating of the film can be defaced due to abrasion, exposure, water and other environmental conditions. As a result, images that are printed to ink-receptive surfaces of card substrates or printed directly to card surfaces should be protected by a protective material that provides both edge-to-edge protection as well as resiliency.
The present invention relates to a protective film for application to a card member and a method of applying a protective film to a card member. The protective film includes a protective overlay and an ink-receptive material. The ink-receptive material includes an ink-receptive coating on a backing layer. The ink-receptive coating is bonded to the protective overlay. The method also includes removing the backing layer from the ink-receptive coating and laminating the ink-receptive coating to a surface of a card member.
Additional embodiments of the present invention are directed to card substrates and identification cards that can be formed in accordance with the above-described method.
Embodiments of the present invention are directed toward a protective film for application to an identification card member or card substrate. By using an ink-receptive material as at least a portion of the protective film, the present invention can provide a durable card member having edge-to-edge protection.
As illustrated in
Ink-receptive coating 132 is applied to substrate layer 134 by roll coating, air knife coating, blade coating, rod or bar coating or a variety of other methods. Coating 132 generally contains inorganic ceramic materials and organic components. The principal ceramic component of ink-receptive coating 132 can be the boehmite form of alumina hydrate (Al2O3). The principal organic component of protective layer 132 is generally a starch or polyvinyl alcohol (PVA). Coating 132 is formed using an alumina sol to which a starch or PVA has been added to at a 5–50% weight percent (typically 10%) level based on alumina hydrate solids. Ink-receptive coating 132 is applied to backing layer 134 such that the final dried layer thickness is in the range of 10–50 microns, and preferably in the range of 20–35 microns. Ink-receptive coating 132 has an average pore radius in the range of 5–20 nanometers, with pore volumes in the range of 0.3–1.0 ml/gram.
The organic portion of coating 132 acts as a binder. It should be noted that the binder can be made of many types of materials. For example, the binder can be made of a styrene-butadiene copolymer rubber (NBR) latex, carboxymethyl cellulose, hydroxymethyl cellulose or polyvinyl pyrrolidone. Coating 132 is applied to backing layer 134. For example, backing layer 134 can include polymeric films and polyester resin, such as PET, polyester diacetate polycarbonate resins, fluroresisns (i.e. ETFE) and polyvinyl chloride resins, paper sheets and synthetic paper sheets. Coating 132 can also contain other materials to provide weather resistance, provide improved light and ozone resistance, assist in the stability of dyes and prevent dye fading. For example, additional polymerizable binders can be used to improve weather resistance, additional magnesium (Mg) and/or thiocyancate (SCN) ions can provide improved light and ozone resistance, additional organic materials such as dithiocarbamates, thiurams, thiocyanate esters, thiocyanates and hindered amines help prevent dye fading and additional non-ionic or cationic water insoluble resins particles can improve coating stability.
Other coatings can be added to coating 132. For example, a silica gel coating can be applied to improve gloss and abrasion resistance and silica agglomerates can be used to promote receptivity for pigmented inks.
Suitable ink-receptive materials 130 are produced by Ikonics Corporation of Duluth, Minn., such as AccuArt™ and AccuBlack™, which are generally used for the production of film positives, negatives, color proofs and full-color presentation transparency displays. The ink-receptive coating of AccuArt™ includes many of the desired features and components for ink-receptive material 130. Although the AccuArt™ film is a suitable film for the present invention, those skilled in the art should recognize that other ink-receptive coatings can be applied to backing layer 134.
As shown in
Ink-receptive material 130, adhesive layer 126 and protective overlay 120 are placed in a device 150 for lamination. For example, device 150 can be hot rollers or lamination plates, both of which can have or not have a liner. Ink-receptive material 130 is laminated to protective overlay 120 under application of heat (in the range of 250–300 degrees Fahrenheit) and pressure. Sufficient pressure must be present to ensure bubble-free lamination. The lamination and adhesive layer 126 cause ink-receptive material 130 to bond directly to protective overlay 120 to form a protective film 110 (
After ink-receptive material 130, adhesive layer 126 and protective overlay 120 exit from device 150, they are cooled to ambient temperature. As illustrated in
In one embodiment, surface 133 (
Laminating section 174 receives a card 144 and a sheet 176 with the sheet 176 preferably covering the entire surface 160 of card member 144. Laminating section 174 includes a heated roller 188 and a backup roller 190. Card member 144 and the adjoining sheet 176 are fed between heated roller 188 and backup roller 190. Heated roller 188 applies heat to sheet 176 while card member 144 and sheet 176 are pinched between heated roller 188 and backup roller 190 to laminate sheets 176 to surface 140 of card member 144. This results in the bonding of ink-receptive coating 132 of sheet 176 to surface 160 of card member 144, as discussed above.
After card package 142 (
In another embodiment, separator 192 can be a soft-hard roller combination 194 as illustrated in
In accordance with another embodiment of the present invention,
To produce continuous rolls of protective overlay 220 with laminated ink-receptive coating 232, protective overlay 220 can be extruded directly onto ink-receptive material 230 in a process called extrusion lamination. The protective overlay 220 and ink-receptive coating 232 produced can be converted into smaller pieces. Alternatively, protective overlay 220 and ink-receptive coating 232 produced can be laminated to a similarly sized card member to be cut into final identification card shapes.
After ink-receptive material 230 and protective overlay 220 exit from device 250, ink-receptive material 230 and protective overlay 220 are cooled to ambient temperature. Backing layer 234 is peeled away from ink-receptive coating 232. The resulting protective overlay 220 bonded to ink-receptive coating 232 is illustrated in
In one embodiment, an image can be printed on ink-receptive coating 232 of ink receptive material 230 prior to lamination to protective overlay 220. In another embodiment, an image can be printed on a card member prior to lamination to protective film 210 (
After laminating ink-receptive coating 232 and protective overlay 220 to card member 244, the card package is allowed to cool to ambient temperature. The resulting identification card 298 is illustrated in
As illustrated in
Ink-receptive material 130 and 230, as utilized in various embodiments illustrated in
In one embodiment of the present invention, a surface of a card member is treated with an anti-static coating. The treated surface of the card member can either be opposite the surface laminated to an ink-receptive coating, on the same surface as the surface laminated to an ink-receptive coating, or a combination thereof. For example, a suitable anti-static coating is Dimethyl Ditallow Ammonium Chloride. Dimethyl Ditallow Ammonium Chloride is the active ingredient in Static Guard™ distributed by the Consumer Products Division of Alberto-Culver USA, Inc. of Melrose Park, Ill. Dimethyl Ditallow Ammonium Chloride effectively eliminates any static build up. For example, measured static charge is essentially zero after application of Static Guard™.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
The present application claims the benefit of U.S. provisional patent applications Ser. Nos. 60/478,490, filed Jun. 13, 2003 and U.S. provisional patent application Ser. No. 60/493,129, filed Aug. 7, 2003; and is a continuation-in-part of U.S. patent application entitled “INK-RECEPTIVE CARD SUBSTRATE,” Ser. No. 10/717,800, filed Nov. 20, 2003 which is a continuation-in-part of U.S. patent application entitled “PRINTER WITH REVERSE IMAGE SHEET,” Ser. No. 09/799,196, filed Mar. 5, 2001, the contents of which are hereby incorporated by reference in their entirety.
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