US 11,954,544 B1
Method for making advanced metal cores for metal cards
Michael Scruggs, Lakeland, FL (US); Lee Shaye Kirkland, Lakeland, FL (US); and Jerry Michael West, Tampa, FL (US)
Assigned to InterActive Cards, Inc., Lakeland, FL (US)
Filed by InterActive Cards, Inc., Lakeland, FL (US)
Filed on May 26, 2022, as Appl. No. 17/825,500.
Claims priority of provisional application 63/308,577, filed on Feb. 10, 2022.
Int. Cl. B05D 7/14 (2006.01); B05D 1/40 (2006.01); B05D 3/00 (2006.01); B05D 3/04 (2006.01); B05D 3/12 (2006.01); B29C 39/10 (2006.01); B29C 39/12 (2006.01); G06K 19/02 (2006.01); B29K 105/02 (2006.01); B29K 705/00 (2006.01); B29L 9/00 (2006.01)
CPC G06K 19/022 (2013.01) [B05D 1/40 (2013.01); B05D 3/007 (2013.01); B05D 3/0466 (2013.01); B05D 3/0493 (2013.01); B05D 3/12 (2013.01); B05D 7/14 (2013.01); B29C 39/10 (2013.01); B29C 39/123 (2013.01); B29K 2105/02 (2013.01); B29K 2705/00 (2013.01); B29L 2009/003 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A process for making a metal core for a metal card, comprising the steps of:
locating a metal core in a reservoir in a process chamber, wherein the metal core is configured with at least one aperture located in a generally planar first surface area of the metal core;
introducing a two-part polymer mixture into the reservoir on top of the first surface of the metal core;
reducing a volume of voids contained in the partially-cured two-part polymer mixture held in the reservoir located in the process chamber by creating a partial vacuum in the process chamber followed by introducing a pressurized inert gas into the pressurized chamber;
removing the metal core with the partially-cured two-part polymer mixture from the process chamber;
allowing the metal core with the partially-cured two-part polymer mixture to cure outside of the process chamber to form a cured metal core; and
treating an upper surface of the cured metal core to reduce an amount of surface irregularities which are located in an upper plane of the upper surface.