[0001]    This application claims the benefit of U.S. Provisional Application No. 61/213,097, filed May 6, 2009, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to cards. More particularly, the present invention relates to texturized cards having features relating to tactile and visual properties on at least one surface. 
         [0004]    2. Description of the Related Art 
         [0005]    A variety of cards formed of different shapes and materials are prevalent in today&#39;s marketplace. For example, cards are frequently used in applications involving transit, identification, security, and financial services, amongst many others. Generally, cards, which are typically planar, possess first and second surfaces having an area far in excess of card thickness. To distinguish amongst providers and applications, as well as to provide unique characteristics, cards can be manufactured with a design or image printed on one or both surfaces. Additional elements such as magnetic stripes, integrated circuits or microchips, holographic security features, etc., may be disposed on or near a card surface or within with card itself. Additionally, cards can be formed having alphanumeric characters embossed on a surface, as is typically done in the personalization of financial transaction cards. Traditional cards lack, however, texturization on one or both surfaces to provide visual and/or tactile properties. What is needed, therefore, is a method and apparatus for imparting texturization on one or more card surfaces. 
       SUMMARY 
       [0006]    The present invention has been developed to address the above and other problems in the related art. According to exemplary embodiments of the present invention, a heating apparatus is disclosed that includes a first region containing a heat source, a second region that is separate from and thermally coupled with the first region via an interface element, and a convection deflector. The convection deflector is disposed within the interior of the first region to direct heat towards the interface element. The deflector can have a geometric shaped cross-section with a front side oriented towards the heat source and an opposing rear side oriented away from the heat source. The front and rear sides are adapted to reflect radiant and convective heat. 
         [0007]    According to exemplary embodiments of the present invention, a method of making a texturized card is disclosed. The method includes providing a card layer having a first surface and providing a release element having a second surface that is textured. The melting point of the release element has a temperature that is higher than the melting point temperature of the card layer. The method further includes positioning the release element against the card layer so that the second surface of the release element is in contact with the first surface of the card layer, then applying heat and pressure in sufficient quantity to enable the texture on the release element to be imparted to the first surface of the card layer. The release element is characterized as being suitable for a limited number of heat and pressure applications than available with a traditional texturized plate. 
         [0008]    Exemplary embodiments of the present invention further disclose a method of making a texturized card. The method includes providing a plurality of card layers, at least one of the layers comprises a polymeric material, one of which being a receiving layer and having a first surface. The method further includes providing a release element having a second surface that is textured. The melting point of the release element has a temperature that is higher than the melting point temperature of the polymeric receiving layer. The method further includes positioning the release element against the polymeric receiving layer so that the textured second surface of the release element is in contact with the first surface of the polymeric receiving layer, then applying heat and pressure to the card layers and release element at sufficient levels to enable the texture on the release element to be imparted to the first surface of the polymeric receiving layer. The release element is characterized as being suitable for a limited number of heat and pressure applications, the number being less than that available with a traditional texturized plate. 
         [0009]    The above and/or other aspects, features and/or advantages of various embodiments will be further appreciated in view of the following description in conjunction with the accompanying figures. Various embodiments can include and/or exclude different aspects, features and/or advantages where applicable. In addition, various embodiments can combine one or more aspect or feature of other embodiments where applicable. The descriptions of aspects, features and/or advantages of particular embodiments should not be construed as limiting other embodiments or the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above and/or other exemplary features and advantages of the preferred embodiments of the present invention will become more apparent through the detailed description of exemplary embodiments thereof with reference to the accompanying drawings, in which: 
           [0011]      FIG. 1  illustrates a sectional view of a card layer and release element in accordance with an embodiment of the present invention; 
           [0012]      FIG. 2  is a flow diagram of a texturized card fabrication process in accordance with an embodiment of the present invention; 
           [0013]      FIG. 3  depicts texturized cards made in accordance with the embodiment of  FIG. 2 ; 
           [0014]      FIG. 4  illustrates a sectional view of a plurality of card layer and release element combinations in accordance with an embodiment of the present invention; and 
           [0015]      FIG. 5  is a flow diagram of a texturized card fabrication process in accordance with an embodiment of the present invention. 
       
    
    
       [0016]    Throughout the drawings, like reference numbers and labels should be understood to refer to like elements, features, and structures. 
       DETAILED DESCRIPTION 
       [0017]    Exemplary embodiments of the present invention will now be described more fully with reference to the accompanying drawings. The matters exemplified in this description are provided to assist in a comprehensive understanding of various embodiments of the present invention disclosed with reference to the accompanying figures. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the claimed invention. Descriptions of well-known functions and constructions are omitted for clarity and conciseness. To aid in clarity of description, the terms “upper,” “lower,” “above,” “below,” “left” and “right,” as used herein, provide reference with respect to orientation of the accompanying drawings and are not intended to be limiting. 
         [0018]    In the manufacture of cards, it is occasionally desirable to produce a card that has a textured surface. Traditionally, lamination plates, which are normally smooth, are worked so as to receive a textured pattern. For example, a die maker will dispose a graphic pattern on a lamination plate in a manner available to those having ordinary skill in the art, such as etching, engraving, photo-lithography, or other like methods. The lamination plate may be made from a variety of metals, such as magnesium, copper, bronze, chrome-plated metal, stainless steel, or other like metals. Although such traditional lamination plates are quite durable, lasting many processing life cycles, they are expensive to produce and the time required to impart a particular texture or design and have it available for production can be very lengthy. Accordingly, a need therefore exists for the ability to rapidly introduce various textures and designs in the card manufacturing process without the need to custom form lamination plates. 
         [0019]    In accordance with exemplary embodiments of the present invention, a release element, which has a textured pattern disposed on at least one of its surfaces, is used to slip over a lamination plate such that a textured side is facing the card material. On application of heat and pressure the textured pattern from the release element with impart to the card material. It is anticipated, though not essential, that the release element will be formed of a material that is less expensive, and likely less durable, than the lamination plate. Accordingly, the release element will have a limited operational life relative to that of the lamination plate. Exemplary embodiments provide for a disposable release element that can be discarded after a limited number of uses. One advantage that a release element has over a traditional lamination plate is that the release element can be quickly and inexpensively produced, thus facilitating rapid design changes. 
         [0020]      FIG. 1  illustrates a sectional view of a card layer and release element in accordance with an embodiment of the present invention. Referring to  FIG. 1 , card layer  100 , having first surface  100   a , and release element  110 , having second surface  110   a , are shown in a position with second surface  110   a  facing towards first surface  100   a . Card layer  100  can be any material suitable for card manufacture. For example, card layer  100  can be made of plastic, vinyl, paper, glass, fiberglass, sheet metal, etc. Although it is anticipated that a texturized card will be formed of multiple layers, thus card layer  100  being one of a plurality of layers, card layer  100  can also be the only layer of the card. Exemplary embodiments provide card layer  100  as being made of a polymeric material. Generally, cards, which are typically planar, possess front and back surfaces having an area far in excess of card thickness. Exemplary embodiments provide for a texturized card that is substantially planar. Cards are frequently used in applications involving transit, identification, security, and financial services, amongst many others. 
         [0021]    Release element  110  can be made from plastic or vinyl, paper, glass, sheet metal, or any material upon which a texture can be formed. Exemplary embodiments provide the release element  110  as being made of paper with a textured side (second surface  110   a ) and a paper backing. The material comprising release element  110  should be, however, of a nature such that release element  110  has a melting point temperature that is higher than the melting point temperature of card layer  100 . In operation, heat will be applied at a level sufficient to soften the card layer  100  material so that on application of adequate pressure the texture from release element  110  will be imparted into the first surface of card layer  100 . 
         [0022]    The texture of second surface  110   a  can be formed of various shapes and designs or, alternatively, can be smooth. A release element  110  having a smooth surface would be useful in situations where a lamination plate has been damaged, thus requiring a covering to protect the card layer  100  during the lamination process. The textured design on release element  110  can be any pattern known to those of ordinary skill in the art and can be disposed substantially continuous across the second surface of the release element  110  or it can be discontinuous such that the textured area can cover an entire surface of the completed card or can be limited to specific regions of the surface in various patterns. In either case, the pattern can form indicia, such as a graphic depiction or lettering, or can be various shapes and icons. 
         [0023]    Exemplary embodiments provide for the card layer and release element to comprise a combination whereby a plurality of card layer and release element combinations can be assembled for the simultaneous processing of multiple texturized cards. 
         [0024]      FIG. 2  is a flow diagram of a texturized card fabrication process in accordance with an embodiment of the present invention. At step  200 , a card layer  100  having a first surface  110   a  is provided. At step  210 , a release element  110  is provided that has a textured second surface  110   a , the melting point temperature of the release element  110  being higher than the melting point temperature of the card layer  100 . At step  220 , the release element  110  is positioned against card layer  100  so that the textured second surface  110   a  is in contact with the first surface  110   a  of card layer  100 . At step  230 , heat and pressure are applied to card layer  100  and release element  110  at sufficient levels to enable the texture of the second surface  110   a  of the release element  110  to be imparted to the first surface  110   a  of the card layer  100 . The release element  110  is suitable for a limited number of heat and pressure applications, the limited number being less than that available with a traditional texturized lamination plate. 
         [0025]      FIG. 3  depicts texturized cards made in accordance with the embodiment of  FIG. 2 . Card  300  illustrates a card made with a card layer  100  having a textured pattern disposed continuously across the surface. Card  310  illustrates a card made with a card layer  100  having a textured pattern comprising a logo and lettering in addition to a geometric shape. 
         [0026]      FIG. 4  illustrates a sectional view of a plurality of card layer and release element combinations in accordance with an embodiment of the present invention. Each combination comprises a card layer and release element as described with  FIG. 1  above. Shown in  FIG. 4 . are combinations  400 / 410 ,  420 / 430 , and  440 / 450 , each card layer having a first surface and each release element having a textured second surface,  400   a / 410   a ,  420   a / 430   a ,  440   a / 450   a , respectively. Additional or fewer card layer/release element combinations can be provided as desired. As discussed with  FIG. 1  above, each combination has the release element positioned against the card layer so that the textured second surface of each release element is in contact with the first surface of each card layer. Heat and pressure are applied to the plurality of card layer and release element combinations at sufficient levels to enable the texture of the second surface of each release element to be imparted to the first surface of each card layer. The release elements  410 ,  430 , and  450  are suitable for a limited number of heat and pressure applications, the limited number being less than that available with a traditional texturized lamination plate. One advantage of assembling a collection of card layer/release element combinations is that the assembly forms a book that can process multiple cards simultaneously. 
         [0027]      FIG. 5  is a flow diagram of a texturized card fabrication process in accordance with an embodiment of the present invention. At step  500 , a plurality of card layers  100  are provided, at least one of the layers comprising a polymeric material, of which one has a first surface  110   a  that serves to receive texturization. At step  510 , a release element  110  is provided that has a textured second surface  110   a , the melting point temperature of the release element  110  being higher than the melting point temperature of the polymeric receiving layer. At step  520 , the release element  110  is positioned against the polymeric receiving layer so that the textured second surface  110   a  is in contact with the first surface  110   a  of the polymeric receiving layer. At step  530 , heat and pressure are applied to the plurality of card layers  100  and release element  110  at sufficient levels to enable the texture of the second surface  110   a  of the release element  110  to be imparted to the first surface  110   a  of the polymeric receiving layer. The release element  110  is suitable for a limited number of heat and pressure applications, the limited number being less than that available with a traditional texturized lamination plate. 
         [0028]    While the present invention has been particularly shown and described with reference to certain exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.
A method of making a texturized card is disclosed. The method includes providing a card layer having a first surface and providing a release element having a second surface that is textured. The melting point of the release element has a temperature that is higher than the melting point temperature of the card layer. The method further includes positioning the release element against the card layer so that the second surface of the release element is in contact with the first surface of the card layer, then applying heat and pressure in sufficient quantity to enable the texture on the release element to be imparted to the first surface of the card layer. The release element is characterized as being suitable for a limited number of heat and pressure applications than available with a traditional texturized plate.