Various types of materials are used to protect plastic cards from abrasion, wear, fading. Alternation, and duplications. Overlay varnishes and laminate patches are the most common materials used to enhance card durability and security.
Card durability has to do with how well the card withstands various forms of environmental stress. They include resistance to abrasion, such as passing the card through a magnetic stripe or bar code reader, protection from image fading when exposed to sunlight, and resistance to damage when immersed in water or exposed to chemicals.
Another important factor in applications such as drivers licensing is resistance to tampering, alteration, and/or replication. With the use of protective materials such as laminate patches with holograms, cards can be constructed to eliminate the potential of tampering and alteration.
Card security means that the card can be verified for authenticity. Techniques include the application of overlay varnish or overlaminate materials with hologram images. Use of these materials in constructing cards makes replication by anyone without access to the custom hologram image materials virtually impossible.
Overlay varnishes provide card protection, but have a much shorter life span that laminate patches – and offer very little security (with the exception of some hologram varnishes). Varnishes are not a solid covering and have multiple tiny holes in the surface, which allows the dyes to be drawn away from the card. This will cause the image on the card to blur and fade due to UV light, shift in color, or just wear away. The life expectancy of a plain plastic card is up to 2 years.
Laminate patches offer better protection than plain varnish, for both security and life expectancy. A patch laminate is, as its name implies, a polyester patch that is applied to the surface of the card after printing. Laminate patches, most often either .6 or 1.0 mil thick are applied via a hot roll laminating station. The life expectancy of a plastic card with a laminate patch is up to seven years.
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