Abstract: Full foil face assemblies and methods for manufacturing the same are provided. The assemblies can be formed by obtaining a first film layer having a maximum thickness that is no greater than 2.0 mils, and applying the first film layer with a reflective or refractive body-containing layer to form a core layer assembly. The reflective or refractive body-containing layer may provide a functional feature and/or decorative feature of a card to be manufactured using the first film layer and the core layer assembly.

Abstract: A method for introducing a reflective, refractive, and/or diffractive variable and/or non-variable image to a substrate by use of thermal transfer printing includes simultaneously transferring a defined portion of each of a protective coating layer, an image layer, and an adhesive layer from a carrier film of a transfer ribbon to the substrate by applying heat to the transfer ribbon. The defined portions of the image layer and the protective coating layer are adhered to the substrate using the adhesive layer. Subsequent to transferring the protective coating layer, the image layer, and the adhesive layer, durability is provided to the image layer by cross-linking the protective coating layer that is over the image layer by exposing the protective coating layer to a radiation source after the defined portions of the protective coating layer, the image layer, and the adhesive layer are transferred from the carrier film.

Abstract: A sheet assembly can be cut into one or more cards. The sheet assembly includes an upper sheet configured to receive a first printing of first indicia for the one or more cards, a polymer core coupled with the upper sheet, and a lower sheet configured to receive a second printing of second indicia for the one or more cards. The lower sheet is coupled with the polymer core with the polymer core disposed between the upper sheet and the lower sheet. The upper sheet, polymer core, and/or the lower sheet is or are formed from a polymer binder with inorganic particles dispersed in the polymer binder. The inorganic particles can have a first density of the inorganic particles that is less than four times a second density of the polymer binder and/or a mass-median-diameter (D50) of the inorganic particles can be larger than ten microns in size.

Abstract: A method for introducing a reflective and/or diffractive metallic variable and/or non-variable image to a substrate by use of thermal transfer printing includes simultaneously transferring a defined portion of each of a protective coating layer, a metal layer, and an adhesive layer from a carrier film of a transfer ribbon to the substrate by applying heat to the transfer ribbon. The defined portions of the metal layer and the protective coating layer are adhered to the substrate using the adhesive layer. Subsequent to transferring the protective coating layer, the metal layer, and the adhesive layer, durability is provided to the metal layer by cross-linking the protective coating layer that is over the metal layer by exposing the protective coating layer to a radiation source after the defined portions of the protective coating layer, the metal layer, and the adhesive layer are transferred from the carrier film.

Abstract: A card assembly includes an insulating planar body and a magnetic stripe assembly coupled with the planar body. The magnetic stripe assembly includes a magnetic layer configured to magnetically store information and a metal layer that provides at least one of a security feature, a decorative feature, or other functional feature. The metal layer has a small thickness such that the metal layer prevents conduction of electrostatic discharge (ESD) through the magnetic stripe assembly.

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.

Abstract: A method for introducing a reflective and/or diffractive metallic variable and/or non-variable image to a substrate by use of thermal transfer printing includes simultaneously transferring a defined portion of each of a protective coating layer, a metal layer, and an adhesive layer from a carrier film of a transfer ribbon to the substrate by applying heat to the transfer ribbon. The defined portions of the metal layer and the protective coating layer are adhered to the substrate using the adhesive layer. Subsequent to transferring the protective coating layer, the metal layer, and the adhesive layer, durability is provided to the metal layer by cross-linking the protective coating layer that is over the metal layer by exposing the protective coating layer to a radiation source after the defined portions of the protective coating layer, the metal layer, and the adhesive layer are transferred from the carrier film.

Abstract: A card assembly includes an insulating planar body and a magnetic stripe assembly coupled with the planar body. The magnetic stripe assembly includes a magnetic layer configured to magnetically store information and a metal layer that provides at least one of a security feature, a decorative feature, or other functional feature. The metal layer has a small thickness such that the metal layer prevents conduction of electrostatic discharge (ESD) through the magnetic stripe assembly.

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.