Foil composite card

Abstract

Composite cards embodying the invention include a clear plastic core layer with an embossed metalized pattern formed on top of, or within, the core layer. A selected number N of clear plastic layers are formed on top of the embossed metalized pattern and a like number N of clear plastic buffer layers are formed below the clear plastic core layer. The metalized pattern is centrally located with layers above and below the pattern to protect the pattern and inhibit the unauthorized alteration of the embossed metalized pattern while enabling the embossed metalized pattern to be visible. Selected ones of the N clear plastic layers include selected information and a window is formed within the pattern to enable the selected information to be seen.

What is claimed is: 
     
         1 . An assembly for forming a document comprising:
 a clear plastic core layer having first and second, spaced apart, surfaces, extending generally parallel to each other;   a pattern embossed on, or in, said first surface of the dear plastic core layer;   a metal or a metal compound vapor deposited on the embossed pattern to form an embossed metalized pattern whereby light incident on the embossed metalized pattern produces a reflected light pattern corresponding to the embossed metalized pattern and wherein the vapor deposited metal, or metal compound, forms a layer which is thin enough to allow see-through; and   a selected number N of clear plastic layers formed on top of the embossed metalized pattern and a like number N of clear plastic buffer layers formed below the second surface of the clear plastic core layer; where N is an integer equal to, or greater than, one; said selected layers for forming a document having an embossed metalized pattern located along said first surface of the clear plastic core layer so as to be centrally located relative to a direction perpendicular to said first and second surfaces of the clear plastic core layer and protected and also for inhibiting the unauthorized alteration of the embossed metalized pattern while enabling the embossed metalized pattern to be visible; and   wherein selected ones of said N clear plastic layers include selected information; and wherein a window is formed within the pattern to enable the selected information to be seen.   
     
     
         2 . An assembly for forming a document as claimed in  claim 1 , wherein the embossed metalized pattern is a customized pattern and wherein said selected number N of clear plastic layers includes a first clear plastic buffer layer attached to the top surface of the embossed metalized pattern via a first clear adhesive layer; where the top surface of the embossed metalized pattern is defined as the portion of the embossed metalized pattern away from the first surface of the clear plastic core layer; and a corresponding second clear plastic buffer layer attached to the second surface of the clear plastic core layer via a second clear adhesive layer; wherein the first and second clear plastic buffer layers have a predetermined thickness and wherein the first and second clear plastic buffer layers are of similar predetermined thickness; and wherein the first and second clear adhesive layers each have a certain thickness and wherein the first and second clear adhesive layers are of approximately the same certain thickness; and
 a third clear plastic layer on which information may be selectively written attached to the first clear plastic layer and a fourth clear plastic layer on which information may be selectively written attached to the second clear plastic layer.   
     
     
         3 . An assembly for forming a document as claimed in  claim 1  wherein the embossed metalized pattern is customized by application of a laser beam. 
     
     
         4 . An assembly for forming a document as claimed in  claim 1 , wherein the embossed metalized pattern is formed on, or in, said first surface of the clear plastic core layer. 
     
     
         5 . An assembly for forming a document as claimed in  claim 4 , wherein the embossed metalized pattern formed on, or in, the first surface of the clear plastic core layer includes a layer of metal vapor deposited on the embossed layered pattern to form a hologram viewable when light is incident on said first surface of the clear plastic core layer; and the layer of the vapor deposited metal is thin enough to enable light to be seen when viewed through the second surface of the clear plastic core layer. 
     
     
         6 . An assembly for forming a document as claimed in  claim 4 , wherein the embossed metalized pattern formed on the surface of the core clear plastic layer includes a metal compound having a high refraction index vapor deposited on the pattern to refract the light incident on the embossed metalized pattern. 
     
     
         7 . An assembly for forming a document as claimed in  claim 1 , wherein the pattern is formed on said first surface of the clear plastic core layer by first depositing an embossing layer on the first surface of the clear plastic core layer and then embossing a desired pattern within the embossing layer. 
     
     
         8 . An assembly for forming a document as claimed in  claim 7 , wherein a layer of metal is vapor deposited on the desired pattern embossed within the embossing layer for forming a hologram viewable when light is incident on said first surface of the clear plastic core layer; and the layer of metal is thin enough to enable light to be seen when viewed through the second surface of the clear plastic core layer. 
     
     
         9 . An assembly for forming a document as claimed in  claim 7 , wherein a metal compound having a high refractive index is vapor deposited on the desired pattern. 
     
     
         10 . An assembly for forming a document as claimed in  claim 1 , wherein said vapor deposited metal, or metal compound, is a few atoms thick so as to be sufficiently thin to allow light to pass through all the layers for enabling see-through while at the same time enabling a visible image to be reflected. 
     
     
         11 . An assembly for forming a document as claimed in  claim 2 , further including a fifth layer attached to the third layer and a sixth layer attached to the fourth layer, and wherein portions of the fifth or sixth layers include printed information. 
     
     
         12 . An assembly for forming a document as claimed in  claim 2 , further including additional layers attached to the third and fourth layers, and wherein portions of selected ones of said additional layers include printed information. 
     
     
         13 . An assembly for forming a document as claimed in  claim 2 , further including additional layers attached to the third and fourth layers, and wherein a selected one of said additional layers includes an integrated circuit (IC) and an antenna for enabling information to be stored in the IC and to be received and transmitted. 
     
     
         14 . An assembly for forming a document as claimed in  claim 2 , further including additional layers attached to the third and fourth layers, and wherein a selected one of said additional layers includes an integrated circuit (IC) and an antenna for enabling information to be stored in the IC and to be received and transmitted; and further including an opening on one side of the assembly for accessing the IC. 
     
     
         15 . An assembly for forming a document as claimed in  claim 2 , further including additional layers attached to the third and fourth layers, and wherein selected ones of said additional layers include at least one of selected information and patterns; and wherein portions of the metal or metal compound vapor deposited on the embossed metalized pattern are removed to enable the selected information and patterns to be seen. 
     
     
         16 . An assembly for forming a document as claimed in  claim 1 , wherein said pattern is customized by applying a laser beam to the pattern.