Patent Publication Number: US-11651184-B2

Title: Systems and methods for producing non-standard shaped cards

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The subject application is a continuation of U.S. patent application Ser. No. 16/733,964, filed Jan. 3, 2020, the complete disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates to the production of cards, and more particularly, to systems and methods for producing non-standard shaped cards. 
     BACKGROUND 
     Many cards, such as credit cards and debit cards, are producing using a CR80 (rectangular) form factor. Accordingly, many or all high throughput machines for putting user information on the cards are set up to run rectangular shapes. When working with other shapes, these machines must be custom build or modified, which can increase costs and delay production while reducing the incentive to develop new and varied card designs. 
     These and other deficiencies exist. Accordingly, there is a need to provide users with an appropriate solution that overcomes these deficiencies and promotes the development of new card designs while reducing development and production costs. 
     SUMMARY 
     Aspects of the disclosed technology include systems and methods for out-of-band authenticity verification of mobile applications. 
     Embodiments of the present disclosure provide a card, comprising: processing circuitry including a chip and memory. The card may include one or more antennas in communication with the chip. The card may include a first layer of material aligned within a perimeter of the card via laminate encapsulation. The first layer of material may comprise a non-rectangular shape. The first layer of material may be offset with a shape of the card. The first layer of material may be in communication with the chip. The first layer of material may comprise at least one selected from the group of steel, tungsten, titanium or any combination thereof. The card may be compliant with one or more form factors. 
     Embodiments of the present disclosure provide a method for producing a card, comprising: producing one or more cards, the one or more cards comprising a non-rectangular shape; personalizing the one or more cards; and customizing a shape of a slug for laminate encapsulation after the personalization of the one or more cards, wherein the shape comprises a non-rectangular shape, and wherein the shape is arranged such that the slug is disposed within a boundary of the one or more cards. 
     Further features of the disclosed design, and the advantages offered thereby, are explained in greater detail hereinafter with reference to specific example embodiments illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1 A  is a diagram of a card according to an example embodiment. 
         FIG.  1 B  is a diagram of a card according to an example embodiment. 
         FIG.  2    is a diagram of a layer of material according to an example embodiment. 
         FIG.  3    is a diagram of a card according to another example embodiment. 
         FIG.  4    is a method illustrating a sequence for producing a card according to an example embodiment. 
         FIG.  5    is a diagram of a card subject to body punching according to an example embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The following description of embodiments provides non-limiting representative examples referencing numerals to particularly describe features and teachings of different aspects of the invention. The embodiments described should be recognized as capable of implementation separately, or in combination, with other embodiments from the description of the embodiments. A person of ordinary skill in the art reviewing the description of embodiments should be able to learn and understand the different described aspects of the invention. The description of embodiments should facilitate understanding of the invention to such an extent that other implementations, not specifically covered but within the knowledge of a person of skill in the art having read the description of embodiments, would be understood to be consistent with an application of the invention. 
     As further described herein, systems and methods may utilize non-rectangular slugs while maintaining a form factor through the end of personalization so that they may be punched into shape at the very end and thus do not require modification to existing machinery. 
       FIG.  1 A  illustrates a card according to an example embodiment. As further discussed below, card  100  may include contact pad  105 , one or more antennas  125 , and a first layer of material  130 . Although  FIG.  1 A  illustrates single instances of the components, card  100  may include any number of components. 
     As illustrated in  FIG.  1 B , the card  100  may also include a contact pad  105 , which may include processing circuitry  110  for storing and processing information, including a chip or processor  115  and a memory  120 . The contact pad  105  may be configured to establish contact with another communication device, such as a user device, smart phone, laptop, desktop, or tablet computer. The card  100  may also include processing circuitry, antenna and other components not shown in  FIG.  1 A . These components may be located behind the contact pad  105 . The card  100  may also include one or more magnetic strips or tapes, which may be located on one or more surfaces of the card  100 . In some examples, the one or more magnetic strips or tapes may be located on the front of the card  100  and in other examples, the one or more magnetic strips or tapes may be located on the back of the card  100 . 
     It is understood that the processing circuitry  110  may contain additional components, including processors, memories, error and parity/CRC checkers, data encoders, anticollision algorithms, controllers, command decoders, security primitives and tamperproofing hardware, as necessary to perform the functions described herein. 
     The memory  120  may be a read-only memory, write-once read-multiple memory or read/write memory, e.g., RAM, ROM, and EEPROM, and the card  100  may include one or more of these memories. A read-only memory may be factory programmable as read-only or one-time programmable. One-time programmability provides the opportunity to write once then read many times. A write once/read-multiple memory may be programmed at a point in time after the memory chip has left the factory. Once the memory is programmed, it may not be rewritten, but it may be read many times. A read/write memory may be programmed and re-programed many times after leaving the factory. It may also be read many times. 
     The processor and memory elements of the foregoing exemplary embodiments are described with reference to the contact pad, but the present disclosure is not limited thereto. It is understood that these elements may be implemented outside of the contact pad  105  or entirely separate from it, or as further elements in addition to processor  115  and memory  120  elements located within the contact pad  105 . 
     In some examples, the card  100  may comprise one or more antennas  125 . The one or more antennas  125  may be placed within the card  100  and around the processing circuitry  110  of the contact pad  105 . For example, the one or more antennas  125  may be integral with the processing circuitry  110  and the one or more antennas  125  may be used with an external booster coil. As another example, the one or more antennas  125  may be external to the contact pad  105  and the processing circuitry  110 . 
     In an embodiment, the coil of card  100  may act as the secondary of an air core transformer. The terminal may communicate with the card  100  by cutting power or amplitude modulation. The card  100  may infer the data transmitted from the terminal using the gaps in the card&#39;s power connection, which may be functionally maintained through one or more capacitors. The card  100  may communicate back by switching a load on the card&#39;s coil or load modulation. Load modulation may be detected in the terminal&#39;s coil through interference. 
     As explained above, the card  100  may be built on a software platform operable on smart cards or other devices having limited memory, such as JavaCard, and one or more or more applications or applets may be securely executed. 
     Referring back to  FIG.  1 A , the card  100  may comprise a contactless card. By way of non-limiting examples, the card  100  may comprise at least one selected from the group of credit card, debit card, gift card, identification card, government card, and transportation card. The card  100  may be in compliance with one or more form factors, including but not limited to CR80 and CR100. It is understood that the card  100  is not limited to a contactless card, and that contact-based or other cards are included within the present disclosure. It is further understood that the present disclosure is not limited to a certain type of card, such as a payment card or an identification card, and the present disclosure includes any type of card. 
     The first layer of material  130  may comprise a slug. For example, the first layer of material  130  may be aligned within a perimeter of the card  100 . In some examples, the first layer of material  130  may comprise a predetermined shape. In some examples, the predetermined shape may comprise one or more apertures configured to house contact pad  105 . The predetermined shape may comprise any shape, including a non-rectangular shape. 
     The non-rectangular shape of the first layer of material  130  may comprise one or more portions, such as edges, sides, and/or corners. For example, any one of the one or more portions may be curved. By way of non-limiting examples, the non-rectangular shape may comprise a circular shape, an oval shape, an elliptical shape, a trapezoidal shape, a horseshoe shape, a bullet shape, a door knob shape, or any other shape. The first layer of material  130  may comprise at least one selected from the group of steel, tungsten, titanium, and/or any combination thereof. 
     The first layer of material  130  may be disposed within the card via laminate encapsulation after personalization of the card  100 . In some examples, personalization of the card  100  may include encoding data, card embossing, and printing data onto a card that is specific to an account or user. Without limitation, personalization may further encompass the addition of one or more images, and/or one or more patterns, which may be based on user preference. Personalization may provide the benefit of distinguishing the card  100  from other cards and the benefit of providing additional security. In some examples, the one or more images may comprise at least one selected from the group of a picture of the user, a picture chosen by the user, a logo, and a security image. In some examples, the one or more patterns may include at least one selected from the group of a pattern chosen by the user, a computer generated pattern, and a randomly generated pattern. The first layer of material  130  may be offset with a shape of the card  100 . For example, the first layer of material  130  may not be used all the way to the edge of the card  100 , and thus may fall within a perimeter of the card  100 . The first layer of material  130  may be in communication with the chip  115  to facilitate contact transactions and/or contactless transactions. 
     The first layer of material  130  may comprise a weight of about 16.3 grams. In some examples, a weight of the first layer of material  130  may exceed a weight of the plastic material contents of the card  100 . In some examples, the weight of the plastic material contents of the card  100  may be less than three grams. By way of example, the first layer of material  130  may comprise a length dimension of at least three inches, and a height dimension of at least 1.5 inches. 
       FIG.  2    is a diagram of a layer of material  200  of a card according to an example embodiment. In some examples, the layer of material  200  may be the same or similar as layer of material  130  of  FIG.  1 A . 
     The first layer of material  200  may comprise a slug. For example, the first layer of material  200  may be aligned within a perimeter of a card, similar to that of card  100 . In some examples, the first layer of material  200  may comprise a predetermined shape. In some examples, the predetermined shape may comprise one or more apertures  205  configured to house a contact pad, similar to contact pad  105 . The predetermined shape may comprise any shape, including a non-rectangular shape. 
     The non-rectangular shape of the first layer of material  200  may comprise one or more portions, such as edges, sides, and/or corners. For example, any one of the one or more portions may be curved. By way of non-limiting examples, the non-rectangular shape may comprise a circular shape, an oval shape, an elliptical shape, a trapezoidal shape, a horseshoe shape, a bullet shape, a door knob shape, or any other shape. The first layer of material  200  may comprise at least one selected from the group of steel, tungsten, tungsten, titanium, and/or any combination thereof. 
     The first layer of material  200  may be disposed within the card via laminate encapsulation after personalization of the card. In some examples, personalization of the card may include encoding data, card embossing, and printing data onto a card that is specific to an account or user. Without limitation, personalization may further encompass the addition of one or more images, one or more patterns, which may be based on user preference. Personalization may provide the benefit of distinguishing the card  100  from other cards and the benefit of providing additional security. In some examples, the one or more images may comprise at least one selected from the group of a picture of the user, a picture chosen by the user, a logo, and a security image. In some examples, the one or more patterns may include at least one selected from the group of a pattern chosen by the user, a computer generated pattern, and a randomly generated pattern. The first layer of material  200  may be in communication with a chip, similar to that of chip  115 , to facilitate contact transactions and/or contactless transactions. 
     The first layer of material  200  may comprise a weight of about 16.3 grams. In some examples, a weight of the first layer of material  200  may exceed a weight of the plastic material contents of the card. By way of example, the first layer of material  200  may comprise a length dimension  210  of at least three inches, and a height dimension  215  of at least 1.5 inches. 
       FIG.  3    is a diagram of a card  300  according to another example embodiment. The card  300  may include a layer of material  305 . In some examples, the layer of material  305  may be the same or similar as layer of material  130  of  FIG.  1 A and  200    of  FIG.  2   . 
     The first layer of material  305  may comprise a slug. For example, the first layer of material  305  may be aligned within a perimeter of a card  300 , similar to that of card  100 . In some examples, the first layer of material  305  may comprise a predetermined shape. In some examples, the predetermined shape may comprise one or more apertures  310 . In some examples, aperture  310  may be configured to house contact pad or placement of chip  315 . The predetermined shape may comprise any shape, including a non-rectangular shape. 
     The non-rectangular shape of the first layer of material  305  may comprise one or more portions, such as edges, sides, and/or corners. For example, any one of the one or more portions may be curved. By way of non-limiting examples, the non-rectangular shape may comprise a circular shape, an oval shape, an elliptical shape, a trapezoidal shape, a horseshoe shape, a bullet shape, a door knob shape, or any other shape. The first layer of material  305  may comprise at least one selected from the group of steel, tungsten, titanium, and any combination thereof. 
     The first layer of material  305  may be disposed within the card  300  via laminate encapsulation after personalization of the card  300 . In some examples, personalization of the card  300  may include encoding data, card embossing, and printing data onto a card that is specific to an account or user. Without limitation, personalization may further encompass the addition of one or more images, one or more patterns, which may be based on user preference. Personalization may provide the benefit of distinguishing the card  100  from other cards and the benefit of providing additional security. In some examples, the one or more images may comprise at least one selected from the group of a picture of the user, a picture chosen by the user, a logo, and a security image. In some examples, the one or more patterns may include at least one selected from the group of a pattern chosen by the user, a computer generated pattern, and a randomly generated pattern. The first layer of material  305  may be offset with a shape of the card  300 . For example, the first layer of material  305  may not be used all the way to the edge of the card  300 , and thus may fall within a perimeter of the card  300 . The first layer of material  305  may be in communication with a chip  315  disposed in aperture  310 , similar to that of chip  115 , to facilitate contact transactions and/or contactless transactions. 
     The first layer of material  305  may comprise a weight of about 16.3 grams. In some examples, a weight of the first layer of material  305  may exceed a weight of the plastic material contents of the card  300 . In some examples, the weight of the plastic material contents of the card  300  may be less than three grams. 
       FIG.  4    illustrates a method  400  for producing a card according to an example embodiment. The card may reference same or similar components as card  100  of  FIG.  1 A ,  FIG.  1 B ,  FIG.  2   , and  FIG.  3    as described above. 
     At block  410 , the method may include a first body punching step. The first body punching may include yield a partially finished card to begin a selected shape. As explained above, the selected shape may comprise a non-standard shape or the predetermined shape. In some examples, the first body punching may return a card that includes a plurality of dimensions exceeding that of CR80. For example, the plurality of dimensions may comprise a width dimension and a length dimension. Thus, the card may include a width and a length that are both greater than that of CR80, thereby distinguishing from CR80. In addition, the card may be comprise the same thickness to that of CR80. In some examples, the first body punching may be performed after a first set of processes. For example, the first set of processes may include but not be limited to plate making and sheet printing, sheet collation, lamination, sheet striping, hot stamping, and chip module milling and implanting, and any combination thereof. It is understood that the first body punching may occur after any one or combination of the first set of processes. 
     At block  420 , the method may include a chip and coding step. For example, coding may be used on a magnetic strip of the card. In some examples, a defined compressed code area may be used, such that a coding within a defined area of the card associated with the shape is used. The chip and magnetic strip coding may be performed after the first body punching and prior the second body punching. 
     At block  430 , the method may include a second body punching step. The second body punching step may yield a smaller size card than that of CR80, and also include the same thickness of CR80. The second body punching may be paired with one or more punching modules and match the selected shape. The selected shape may comprise a non-standard shape or the predetermined shape, as previously described above. In some examples, the non-standard shape or the predetermined shape may be programmed as part of a card selection process when a user applies for the card. Moreover, the card may include an antenna configured for the non-standard shape or the predetermined shape of the second body punching step. In some examples, the second body punching may be performed prior to a pairing process in which the card may be brought to the one or more punching modules for the finished shape personalization. In some examples, the second body punching may be performed after a second set of processes. In some examples, the second set of processes may include one or more of the first body punching, chip and magnetic strip coding, and marking by laser engraving. It is understood that the second body punching may occur after any one or combination of the second set of processes. 
       FIG.  5    is a diagram  500  of a card subject to body punching according to an example embodiment.  FIG.  5    may reference same or similar components as card  100  of  FIG.  1 A ,  FIG.  1 B ,  FIG.  2   ,  FIG.  3   , and  FIG.  4   , as described above. 
     Card  505  may include a chip  515 . In some examples, card  505  may be same or similar to card  100 . Chip  515  may be same or similar to chip  115 . Card  505  may be subject to application of a first body punching step. The first body punching may include yield a partially finished card to begin a selected shape. As explained above, the selected shape may comprise a non-standard shape or the predetermined shape. In some examples, the first body punching may return a card that includes a plurality of dimensions exceeding that of a form factor  510 , such as CR80. For example, the plurality of dimensions may comprise a width dimension and a length dimension. Thus, the card may include a width and a length that are both greater than that of CR80, thereby distinguishing from CR80. In addition, the card  505  may be comprise the same thickness to that of CR80. In some examples, the first body punching may be performed after a first set of processes. For example, the first set of processes may include but not be limited to plate making and sheet printing, sheet collation, lamination, sheet striping, hot stamping, and chip module milling and implanting, and any combination thereof. It is understood that the first body punching may occur after any one or combination of the first set of processes. 
     In some examples, coding may be used on a magnetic strip of the card  505 . In some examples, a defined compressed code area may be used, such that a coding within a defined area of the card  505  associated with the shape is used. The chip and magnetic strip coding may be performed after the first body punching and prior a second body punching. 
     The second body punching step may yield a smaller size card, such as card  520  or card  535 , than that of form factor  510 , and also include the same thickness of form factor  510 . The second body punching may be paired with one or more punching modules and match the selected shape. The selected shape may comprise a non-standard shape or the predetermined shape  530 ,  540 , as previously described above. In some examples, the non-standard shape or the predetermined shape  530 ,  540  may be programmed as part of a card selection process when a user applies for the card  505 . In one example, card  520  may include shape  530  which may comprise a non-rectangular shape, such as horseshoe shape or a bullet shape or the like, similar to slug  130 . In another example, card  535  may include shape  540  which may comprise another non-rectangular shape of slug, similar to slug  130 . In either example, shape  530 ,  540  may comprise one or more rounded corners and/or one or more non-rounded corners, or any combination thereof. In addition, it is understood that any other shapes may be used. 
     Moreover, the card  505  may include an antenna  525  configured for the non-standard shape or the predetermined shape  530 ,  540  of the second body punching step. In some examples, the second body punching may be performed prior to a pairing process in which the card  505  may be brought to the one or more punching modules for the finished shape personalization. In some examples, the second body punching may be performed after a second set of processes. In some examples, the second set of processes may include one or more of the first body punching, chip and magnetic strip coding, and marking by laser engraving. It is understood that the second body punching may occur after any one or combination of the second set of processes. 
     The present disclosure includes one or more shaped cards, including but not limited to square, elliptical, non-rectangular, rectangular, triangular, or any other shaped cards. In some examples, the card may comprise a contactless card or a contact-based card. By way of non-limiting examples, the card may be at least one selected from the group of credit card, debit card, gift card, identification card, government card, loyalty program card, and transportation card. In some examples, the card may be compliant with one or more form factors, including but not limited to CR80 and CR100, however, it is understood that non-compliant cards are within the scope of the present disclosure. 
     Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form. 
     In this description, numerous specific details have been set forth. It is to be understood, however, that implementations of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “some examples,” “other examples,” “one example,” “an example,” “various examples,” “one embodiment,” “an embodiment,” “some embodiments,” “example embodiment,” “various embodiments,” “one implementation,” “an implementation,” “example implementation,” “various implementations,” “some implementations,” etc., indicate that the implementation(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every implementation necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrases “in one example,” “in one embodiment,” or “in one implementation” does not necessarily refer to the same example, embodiment, or implementation, although it may. 
     As used herein, unless otherwise specified the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner. 
     While certain implementations of the disclosed technology have been described in connection with what is presently considered to be the most practical and various implementations, it is to be understood that the disclosed technology is not to be limited to the disclosed implementations, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 
     This written description uses examples to disclose certain implementations of the disclosed technology, including the best mode, and also to enable any person skilled in the art to practice certain implementations of the disclosed technology, including making and using any devices or systems and performing any incorporated methods. The patentable scope of certain implementations of the disclosed technology is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.