Patent Publication Number: US-10311350-B2

Title: Transaction card having internal magnetic stripe

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 16/167,983, filed Oct. 23, 2018, which is a continuation of U.S. patent application Ser. No. 15/958,392, filed Apr. 20, 2018, which is a continuation of U.S. patent application Ser. No. 15/887,536, filed Feb. 2, 2018, which is a continuation of U.S. patent application Ser. No. 15/698,419, filed Sep. 7, 2017(now U.S. Pat. No. 9,978,008), which is a continuation of U.S. patent application Ser. No. 15/698,307, filed Sep. 7, 2017, which claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application Ser. No. 62/385,220, filed Sep. 8, 2016, the disclosures of which are expressly incorporated herein by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     The disclosed embodiments generally relate to transaction cards, and particularly, to transaction cards having an internal magnetic stripe. 
     BACKGROUND 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 62/385,220filed Sep. 8, 2016, the contents of which are hereby incorporated in their entirety. 
     Transaction cards, such as credit and debit cards, have increasingly become a primary means for customers to complete financial transactions. Typically, transaction cards are cut from laminated sheets of polyvinyl chloride (PVC) or polycarbonate (PC), or other similar materials. After the overall shape of the card is formed, the card may be modified to add functional and/or visual features. For example, a magnetic stripe and/or microchip may be affixed to one side, the card may be stamped with the card number and customer name, and color or a design may be added for appearance. The magnetic stripe is typically affixed to an exterior surface of the card. 
     As transaction cards increase in prevalence, expectations for transaction card quality have increased. Transaction cards have increasingly been made to meet higher standards regarding materials, durability, and especially security. For example, in traditional cards, the magnetic stripes are exposed on the exterior of the cards, and are easy to tamper with. The magnetic stripes can be removed relatively easily, and the code information relating to an account recorded on the magnetic stripe can be quickly stolen with a low-cost reading device. 
     The present disclosure is directed to overcoming one or more of the problems set forth above and/or other problems associated with conventional/traditional transaction cards. 
     SUMMARY 
     The disclosed embodiments include a transaction card. The transaction card can include a card frame having a card inlay and a card housing. The transaction card can, also, include a magnetic stripe disposed inside the card frame between the card inlay and the card housing. 
     The transaction card can further include, in some aspects, a pocket containing the magnetic stripe. The pocket can be defined by the card inlay or the card housing. In some aspects, the pocket can be defined by the inner surface of the card inlay or the inner surface of the card housing. In some aspects, a first portion of the pocket can be defined by an inner surface of the card inlay, and a second portion of the pocket can be defined by an inner surface of the card housing. 
     The transaction card can further include, in some aspects, a card frame that has a first curved shape and a magnetic stripe that has a second curved shape. In some aspects, the magnetic stripe can be located at a distance of 100-190 microns to an exterior surface of the card inlay or the card housing. In some aspects, the magnetic stripe can be a high output magnetic stripe. 
     The transaction card can further include, in some aspects, a stripe indicator located on an exterior surface of the card frame. In some aspects, the stripe indicator can be located at the same location with respect to edges of the card frame as the magnetic stripe. 
     Consistent with another disclosed embodiment, a method of manufacturing a transaction card is provided. The method can include forming a card inlay, forming a card housing, forming a pocket in at least one of the card inlay and the card housing, positioning a magnetic stripe on at least one of an inner surface of the card inlay and an inner surface of the card housing at a location corresponding to the pocket, and attaching the card inlay to the card housing to form a card frame. In some aspects, the magnetic stripe can be disposed inside the card frame between the card inlay and the card housing and within the pocket. 
     The method can further include, in some aspects, forming a stripe indicator on an exterior surface of the card inlay or the card housing to indicate a location of the magnetic stripe inside the card frame. The method can further include, in some aspects, forming the stripe indicator at the same location with respect to edges of the card frame as the magnetic stripe. 
     The method can further include, in some aspects, forming the card inlay and the card housing by an injection molding process. In some aspects, the method can further include forming the pocket by an injection molding process. In another aspect, the method can further include forming the pocket by a Computer Numerical Control (CNC) process after the injection molding process 
     The method can further include, in some aspects, forming the pocket in the inner surface of the card housing or forming the pocket in the inner surface of the card inlay. The method can further include, in some aspects, forming a first portion of the pocket in an inner surface of the card inlay and forming a second portion of the pocket in an inner surface of the card housing. 
     The method can further include, in some aspects, positioning the magnetic stripe at a distance of 100-190 microns to an exterior surface of the card inlay or the card housing. 
     Consistent with another disclosed embodiment, a transaction card is provided. The transaction card can include a curved card frame having a card inlay and a card housing. The transaction card can further include a first recessed portion in the card inlay and a second recessed portion in the card housing that corresponds to the first recessed portion. In some aspects, the first recessed portion and the second recessed portion can together form a pocket. The transaction card can further include a curved magnetic stripe that can be disposed within the pocket. The transaction card can further include a stripe indicator disposed on an exterior surface of the card frame. 
     The transaction card can further include, in some aspects, a magnetic stripe that occupies an entire space of the pocket such that the magnetic stripe is constrained in at least a thickness direction. In some aspects, the transaction card can further include an adhesive layer inside the pocket. The magnetic stripe can be affixed to the first recessed portion or the second recessed portion by the adhesive layer. The magnetic stripe can be located at a distance of 100-190 microns to an exterior surface of the card inlay or the card housing. 
     In some aspects, the card frame of the transaction card can have a curvature that is the same as the curvature of the magnetic stripe. In other aspects, the curvature of the card frame and the curvature of the magnetic stripe can be different. 
     The transaction card can further include a stripe indicator that has a color that is different from a color of the exterior surface of the card frame. In other aspects, the stripe indicator can have a printed pattern that is not present in the exterior surface of the card frame. In some aspects, the stripe indicator can have a texture that is different from the texture of the exterior surface of the card frame. The stripe indicator can also include icons or texts. The icons or texts can indicate a location of the magnetic stripe. 
     Consistent with another disclosed embodiment, a method of manufacturing a transaction card is provided. The method can include forming a curved card frame. The card frame can include a card inlay and a card housing. The method can further include forming a first recessed portion in the card inlay, forming a second recessed portion that corresponds to the first recessed portion in the card housing, attaching the card inlay to the card housing to form a pocket defined by the first recessed portion to the second recessed portion, positioning a curved magnetic stripe within the pocket, and disposing a stripe indicator on an exterior surface of the card frame. 
     The method can further include, in some aspects, providing a magnetic stripe that occupies an entire space of the pocket such that the magnetic stripe is constrained in at least a thickness direction. The method can further include, in some aspects, disposing an adhesive layer inside the pocket and fixing the magnetic stripe to the first recessed portion or the second recessed portion by the adhesive layer. The magnetic stripe can be located at a distance of 100-190 microns to an exterior surface of the card inlay or the card housing. In some aspects, the magnetic stripe can have a curvature that is the same as the curvature of the card frame. In other aspects, the magnetic stripe can have a curvature that is different from the curvature of the card frame. 
     The method can further include, in some aspects, disposing a stripe indicator that has a color that is different from a color of the exterior surface of the card frame. In some aspects, the stripe indicator can have a printed pattern that is not present in the exterior surface of the card frame. In other aspects, the stripe indicator can have a texture that is different from a texture of the exterior surface of the card frame. In some aspects, the stripe indicator can have icons or texts. The icons or texts can indicate a location of the magnetic stripe. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed embodiments, as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and, together with the description, serve to explain the disclosed embodiments. In the drawings: 
         FIG. 1  is a block diagram of an exemplary transaction system, consistent with disclosed embodiments; 
         FIG. 2  illustrates an exemplary transaction card, consistent with the disclosed embodiments. 
         FIG. 3  is a top view of a traditional transaction card. 
         FIG. 4  is a top view of an exemplary transaction card, consistent with the disclosed embodiments. 
         FIGS. 5A and 5B  show cross-sectional views of the exemplary transaction card shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments. 
         FIG. 6A  schematically shows an exemplary magnetic stripe adhered to an inner surface of a card inlay, consistent with the disclosed embodiments. 
         FIG. 6B  schematically shows an exemplary magnetic stripe  410  adhered to an inner surface of a card housing, consistent with the disclosed embodiments. 
         FIG. 7  illustrates a cross-sectional view of the exemplary transaction card shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments. 
         FIGS. 8A and 8B  show cross-sectional views of the exemplary transaction card shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments. 
         FIGS. 9A and 9B  show top views of an exemplary transaction card, consistent with the disclosed embodiments. 
         FIG. 10  is a flowchart illustrating an exemplary method for manufacturing a transaction card, consistent with the disclosed embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the disclosed embodiments, examples of which are illustrated in the accompanying drawings. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     Disclosed embodiments include cards and methods for manufacturing cards, such as transaction cards. The term “transaction card,” as used herein, refers to any physical card product that is configured to provide information, such as financial information (e.g., card numbers, account numbers, account balance, etc.), quasi-financial information (e.g., rewards balance, discount information, etc.), and/or individual-identifying information (e.g., name, address, etc.), when the card is read by a card reader. Examples of transaction cards include credit cards, debit cards, gift cards, rewards cards, frequent flyer cards, merchant-specific cards, discount cards, etc., but are not limited thereto. The term “transaction card” may include an identification card such as a passport card, a driver&#39;s license, an entry point access card, or the like. The physical properties of the transaction card (e.g., size, flexibility, location of various components included in the card) may meet the various international standards, including, e.g., ISO/IEC 7810, ISO/IEC 7811, ISO/IEC 7812, ISO/IEC 7813, ISO/IEC 7816, ISO 8583, ISO/IEC 4909, and ISO/IEC 14443. For example, a transaction card may have a dimension of 85.60 mm (width) by 53.98 mm (height) by 0.76 mm (thickness), as specified in ISO/IEC 7810. 
     Disclosed embodiments may improve transaction card security by embedding the magnetic stripe inside the card, e.g., between two pieces (card housing and card inlay) of the card in a two-piece card construction. By disposing the magnetic stripe inside the card, it is more difficult to steal information stored in the stripe. Any attempt to remove the stripe from the card may destroy the stripe or damage other parts of the card. In addition, disposing the magnetic stripe inside the card protects the magnetic stripe from other outside objects, thereby reducing wear and tear. Moreover, by disposing the magnetic stripe inside the card, the magnetic stripe can be affixed to the card more securely. Disposing the magnetic stripe inside the card also eliminates the potential problem of delamination in existing card designs that may be caused by flexure (e.g., bending) of the cards or by wear and tear. Finally, by disposing the magnetic stripe inside the card, more space is available on the surface of the card for ornamental design to provide better aesthetics. 
       FIG. 1  illustrates an exemplary transaction system  100 . Transaction system  100  may include a computing system configured to receive and send information between the components of transaction system  100  and components outside of transaction system  100 . Transaction system  100  may include a financial service provider system  110  and a merchant system  120  communicating with each other through a network  130 . Transaction system  100  may include additional and/or alternative components. 
     Financial service provider system  110  may include one or more computer systems associated with an entity that provides financial services. For example, the entity may be a bank, credit union, credit card issuer, or other type of financial service entity that generates, provides, manages, and/or maintains financial service accounts for one or more customers. Financial service accounts may include, for example, credit card accounts, checking accounts, savings accounts, loan accounts, reward accounts, and any other types of financial service accounts. Financial service accounts may be associated with physical financial service transaction cards, such as credit or debit cards that customers use to perform financial service transactions, such as purchasing goods and/or services online or at a point of sale (POS) terminal. Financial service accounts may also be associated with electronic financial products and services, such as a digital wallet or similar account that may be used to perform electronic transactions, such as purchasing goods and/or services online. 
     Merchant system  120  may include one or more computer systems associated with a merchant. For example, merchant system  120  may be associated with an entity that provides goods and/or services (e.g., a retail store). The merchant may include brick-and-mortar location(s) that a customer may physically visit and where the customer may purchase goods and services using the transaction cards. Such physical locations may include computing devices (e.g., merchant system  120 ) that perform financial service transactions with customers (e.g., POS terminal(s), kiosks, etc.). Additionally or alternatively, merchant system  120  may be associated with a merchant who provides an electronic shopping environment, such as a website or other online platform that consumers may access using a computer through a browser, a mobile application, or similar software. Merchant system  120  may include a client device, such as a laptop computer, desktop computer, smart phone, or tablet, which a customer may operate to access the electronic shopping mechanism. 
     Network  130  may include any type of network configured to facilitate communications and data exchange between components of transaction system  100 , such as, for example, financial service provider system  110  and merchant system  120 . Network  130  may include a Local Area Network (LAN) or a Wide Area Network (WAN), such as the Internet. Network  130  may be a single network or a combination of networks. Network  130  is not limited to the above examples and transaction system  100  may employ any type of network that allows entities (shown and not shown) of transaction system  100  to exchange data and information. 
     Transaction system  100  may be configured to conduct a transaction using a transaction card  140 . In some embodiments, financial service provider system  110  may provide transaction card  140  to a customer for use in conducting transactions associated with a financial service account held by the customer. For example, the customer may use transaction card  140  at a merchant location to make a purchase. During the course of the purchase, information may be transferred from transaction card  140  to merchant system  120  (e.g., a point of sale device). Merchant system  120  may communicate with financial service provider system  110  via network  130  to verify the information and to complete or deny the transaction. For example, merchant system  120  may receive account information from transaction card  140 . Merchant system  120  may transmit the account information and a purchase amount, among other transaction information, to financial service provider system  110 . Financial service provider system  110  may settle the transaction by transferring funds from the customer&#39;s financial service account to a financial service account associated with the merchant. 
     While transaction system  100  and transaction card  140  are depicted and described in relation to transactions that involve customers, merchants, and financial service providers, it should be understood that these entities are used only as an example to illustrate one environment in which transaction card  140  may be used. Moreover, it should be understood that transaction card  140  is not limited to financial products and may be any physical card product that is configured to provide information to another device. For example, transaction card  140  may be an identification card configured to provide information to a device in order to identify the holder of the card (e.g., driver&#39;s license) or provide information about the holder of the card (e.g., insurance card). 
     In some embodiments, transaction card  140  may further include a transaction component  144  disposed on or in a transaction card frame (“card frame”)  142 . As used herein, a “transaction component” may be one or more devices and/or elements configured to receive, store, process, provide, transfer, send, delete, and/or generate information. For example, transaction component  144  may be a microchip (e.g., an Europay, MasterCard, and Visa (EMV) chip), a communication device (e.g., Near Field Communication (NFC) antenna, Bluetooth® device, WiFi device), a magnetic stripe, a barcode, Quick Response (QR) code, or a combination thereof. Transaction component  144  may be secured (or affixed, attached) to card frame  142  in such a way that allows card frame  142  to carry transaction component  144  while maintaining a utility of transaction component  144  (i.e., allowing transaction component  144  to interact with merchant system  120 ). 
       FIG. 2  illustrates an exemplary transaction card  140 , consistent with the disclosed embodiments. In the embodiment of  FIG. 2 , transaction card  140  includes a two-piece construction. For example, card frame  142  may include two separate, independently removable card components: a lower card component  202  and an upper card component  204 . Lower and upper card components  202 ,  204  may be referred to as first and second card components, or vice versa. Although lower and upper card components  202  and  204  are shown as having a planar (e.g., flat) shape, it is understood that one or both of them may have a curved shape (e.g., having a curved surface). 
     In one embodiment, card frame  142  may include a construction in which lower card component  202  forms a cavity or space  206  (hence lower card component  202  may be referred to as a “card housing”) and upper card component  204  forms an inlay component (hence upper card component  204  may also be referred to as a “card inlay”) configured to be seated within space  206 . It should be understood, however, that other configurations are possible. For example, transaction card  140  may include a “bucket-and-lid” construction in which lower card component  202  forms a container and upper card component  204  forms a lid that is configured to close the container and that rests on a rim of lower card component  202 . Lower card component  202  and upper card component  204  may be securable to each other to at least partially define space  206  to accommodate transaction component  144 . 
     Lower card component  202  and upper card component  204  may be permanently or temporarily secured to each other to form a complete card frame  142 . For example, lower card component  202  may be secured to upper card component  204  using an adhesive, or by over-molding, pressure fit, interference fit, clasp, tongue-in-groove, post-and-hole, etc. If lower card component  202  and upper card component  204  are temporarily secured to each other, an attachment feature (e.g., for hinged attachment, sliding attachment, etc.) may be included to allow card frame  142  to be disassembled. Other techniques for securing lower card component  202  to upper card component  204  may be apparent to those of skill in the art. 
     In some embodiments, as shown in  FIG. 2 , transaction component  144  may include a first transaction component  230  and a second transaction component  235  that are positioned within enclosed space  206 . First transaction component  230  may be a microchip and second transaction component  235  may be a Near Field Communication (NFC) antenna. It should be understood that first transaction component  230  and second transaction component  235  are examples, and that other configurations are possible (e.g., transaction card  140  may include additional and/or alternative transaction components, or may include only one of first and second transaction components  230  and  235 ). 
       FIG. 3  is a top view of a traditional transaction card  300 . The top view may be a front review or a back view of traditional transaction card  300 . As shown in  FIG. 3 , traditional transaction card  300  includes a card frame  305  and a magnetic stripe  310  provided on an exterior surface of card frame  305 . The magnetic stripe may be provided on a front side or a back side of card frame  305 . In either configuration, in a traditional transaction card, the magnetic stripe is affixed to and exposed on an exterior of the card frame, as shown in  FIG. 3 . 
     For traditional transaction cards, current industry practice may apply an over-lamination over the card surfaces (including the magnetic stripe) with an adhesive. The current over-lamination used in the industry is sufficiently thin to allow the magnetic stripe to be read by a card reader. The over-lamination also serves as additional securing mechanism for holding the magnetic stripe to the card. However, the over-lamination is typically applied during the card printing process (e.g., printed by a card printer), after the card frame with the magnetic stripe has been made. The extra process of applying the over-lamination increases the cost of card production. 
     In traditional card manufacturing processes, injection molding is typically not used. Thus, while the industry practice may use thick laminations to improve protection and fixation of the magnetic stripe, the card manufacturing industry has not yet considered technologies for disposing the magnetic stripe inside the card during a card manufacturing process. 
       FIG. 4  is a top view of an exemplary transaction card  400  consistent with the disclosed embodiments. As shown in  FIG. 4 , transaction card  400  includes a card frame  405  and a magnetic stripe  410  disposed inside the card frame (the dashed line indicates that magnetic stripe  410  is disposed inside the card frame). Magnetic stripe  410  may be disposed at a location corresponding to a location where a traditional magnetic stripe would appear on a card. For example, magnetic stripe  410  may be disposed 1-3 mm inward from an outer edge of transaction card  400  (e.g., distance d from the top edge shown in  FIG. 4  may be 1-3 mm). The shape of transaction card  400  may be any suitable shape, such as rectangular, triangular, circular, or a combination of any shapes. The dimension of magnetic stripe  410  may be any suitable dimension. For example, the dimension of magnetic stripe  410  may follow the Visa® standards or ISO standards. 
       FIGS. 5A and 5B  show cross-sectional views of the exemplary transaction card  400  shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments.  FIGS. 5A and 5B  show that magnetic stripe  410  is disposed inside card frame  405 . In a two-piece construction, card frame  405  may include a first card component  411  (also referred to as “card inlay  411 ”) and a second card component  412  (also referred to as “card housing  412 ”). Card frame  405  may be similar to card frame  142  shown in  FIG. 2 . 
     Referring now to  FIG. 5A , to accommodate magnetic stripe  410  disposed inside card frame  405 , a pocket or cavity (e.g., pocket  420 ) may be formed in at least one of card inlay  411  or card housing  412 .  FIG. 5A  shows the configuration in which pocket  420  is formed in card inlay  411 .  FIG. 5B  shows the configuration in which pocket  420  is formed in card housing  412 . As shown in  FIGS. 5A and 5B , magnetic stripe  410  is disposed within pocket  420 , and affixed to an inner surface of card inlay  411  (shown in  FIG. 5A ) or card housing  412  (shown in  FIG. 5B ). Although magnetic stripe  410  is shown to occupy a space less than the entire space of pocket  420 , it is understood that magnetic stripe  410  may occupy the entire space of pocket  420 . 
     Pocket  420  may be formed in an inner surface of at least one of card inlay  411  or card housing  412 . The inner surfaces of card inlay  411  and card housing  412  are the respective surfaces that face each other when they are attached to each other to form card frame  405 . Pocket  420  may be formed during a molding process (e.g., an injection molding process) when card frame  405  (e.g., card inlay  411  and card housing  412 ) is made. For example, pocket  420  may be formed in a same injection molding process as card inlay  411  and/or card housing  412 . Alternatively or additionally, pocket  420  may be formed subsequent to the formation of card frame  405  (e.g., card housing  412  and/or card inlay  411 ), such as by a computer numerical control (CNC) machining process. After card frame  405  (e.g., card inlay  411  and/or card housing  412 ) is formed, pocket  420  may be formed in card inlay  411  and/or card housing  412  by a separate CNC machining process. The CNC machining process may include milling, laser cutting, grinding, lathing, etc. For example, a portion of material may be removed from an inner surface of card inlay  411  and/or an inner surface of card housing  412  to form pocket  420 . 
     In one embodiment, as shown in  FIG. 5B , pocket  420  is formed in the inner surface of card housing  412 , either by the injection molding process or by the machining process. Magnetic stripe  410  may be disposed within pocket  420 . For example, after pocket  420  is formed in card housing  412 , an adhesive layer (not shown) may be placed in pocket  420 . Magnetic stripe  410  may be placed onto the adhesive layer and secured to an inner surface of card housing  412  by the adhesive layer. Card inlay  411  and card housing  412  may then be assembled (e.g., attached) together to form card frame  405 , with magnetic stripe  410  being positioned within pocket  420 .  FIG. 5B  schematically shows that magnetic stripe  410  is positioned in pocket  420  provided in an inner surface of card housing  412  when card frame  405  is formed. In some embodiments, an adhesive layer may not be used. Magnetic stripe  410  may be placed within pocket  420  and be securely held by card inlay  411  and card housing  412  when they are attached to each other to form card frame  405 . It is understood that when an adhesive layer is not used, magnetic stripe  410  may occupy the entire space of pocket  420 , at least in the thickness direction of card frame  405 , such that magnetic stripe  410  is constrained in at least the thickness direction. 
     Magnetic stripes are classified into low output magnetic stripes and high output magnetic stripes based on their output signal amplitudes. “High output” means the signal amplitude output from the magnetic stripe, when read by a card reader, is higher than a predetermined threshold (e.g., greater than 100% ISO output specification, such as 130%, 150%, 160%, 180%, etc.). Low output means the signal amplitude output from the magnetic stripe, when read by the card reader, is lower than or equal to a predetermined threshold (e.g., lower than or equal to 100% ISO output specification). In the disclosed embodiments, because the magnetic stripe is disposed inside the card frame, high output magnetic stripes may be used. High output magnetic stripes are currently used in metal cards to overcome the interference created by the metal material, which may cause card reading failure. 
     As shown in  FIGS. 5A-5B , magnetic stripe  410  may be disposed inside card frame  405  at a distance D from a surface of card frame  405 . The surface may be an exterior surface of card inlay  411  (shown in  FIG. 5A ) or card housing  412  (shown in  FIG. 5B ). The distance D represents a thickness of the material between magnetic stripe  410  and a card reader (e.g., a thickness through which material magnetic stripe  410  has to “work” in order to output a signal). The distance D may be a function of material properties and manufacturing process constraints. In some embodiments, the distance D may be within a range of 100-190 microns. Within this range, a high output magnetic stripe can output a signal that is sufficient for a card reader to capture information coded on the magnetic stripe. It is understood that in some embodiments, the distance D may be less than 100 microns or greater than 190 microns. It is understood from  FIGS. 5A and 5B  that the distance D also represents the distance from pocket  420  to an exterior surface of card inlay  411  or card housing  412 . 
     Referring now to  FIG. 6A , when pocket  420  is formed in the inner surface of card housing  412 , magnetic stripe  410  may be disposed within pocket  420  through another process. For example, magnetic stripe  410  may be affixed to the inner surface of card inlay  411  (which does not have a pocket) though an adhesive layer (not shown) before card inlay  411  and card housing  412  are assembled together to form card frame  405 . Magnetic stripe  410  may be adhered to the inner surface of card inlay  411  at a location that corresponds to the location of pocket  420  in the inner surface of card housing  412 , such that magnetic stripe  410  is aligned with pocket  420  when card inlay  411  and card housing  412  are attached to each other. 
       FIG. 6A  schematically shows that magnetic stripe  410  is affixed to an inner surface of card inlay  411 , and when card inlay  411  is assembled with card housing  412 , magnetic stripe  410  is disposed within pocket  420 . Although magnetic stripe  410  is shown to occupy less than the entire space of pocket  420 , it is understood that magnetic stripe  410  may occupy the entire space of pocket  420 . In some embodiments, an adhesive layer may not be used. Magnetic stripe  410  may be placed within pocket  420  and be securely held by card inlay  411  and card housing  412  when they are attached to each other to form card frame  405 . It is understood that when an adhesive layer is not used, magnetic stripe  410  may occupy the entire space of pocket  420 , at least in the thickness direction of card frame  405 , such that magnetic stripe  410  is constrained in at least the thickness direction. 
     Likewise, when pocket  420  is formed in the inner surface of card inlay  411 , as shown in  FIGS. 5A and 6B , either by the injection molding process or by the machining process, magnetic stripe  410  may be disposed within pocket  420  via suitable processes similar to those discussed above. For example, in one process, after pocket  420  is formed in card inlay  411 , an adhesive layer (not shown) may be placed in pocket  420 . Magnetic stripe  410  may be placed onto the adhesive layer and secured to an inner surface of card inlay  411  by the adhesive layer, as shown in  FIG. 5A . Card inlay  411  and card housing  412  may then be assembled together to form card frame  405 .  FIG. 5A  schematically shows that magnetic stripe  410  is positioned in pocket  420  provided in an inner surface of card inlay  411  when card frame  405  is formed. In some embodiments, an adhesive layer may not be used. Magnetic stripe  410  may be placed within pocket  420  and be securely held by card inlay  411  and card housing  412  when they are attached to each other to form card frame  405 . It is understood that when an adhesive layer is not used, magnetic stripe  410  may occupy the entire space of pocket  420 , at least in the thickness direction of card frame  405 , such that magnetic stripe  410  is constrained in at least the thickness direction. 
     In another embodiment, as shown in  FIG. 6B , magnetic stripe  410  may be adhered to the inner surface of card housing  412  (which does not have a pocket) through an adhesive layer (not shown) before card inlay  411  and card housing  412  are assembled together. Magnetic stripe  410  may be adhered to the inner surface of card housing  412  at a location that corresponds to the location of pocket  420  on the inner surface of card inlay  411 , such that magnetic stripe  410  is aligned with pocket  420  when card inlay  411  and card housing  412  are assembled.  FIG. 6B  schematically shows that magnetic stripe  410  is adhered to an inner surface of card housing  412 , and when card inlay  411  is assembled with card housing  412 , magnetic stripe  410  is disposed within pocket  420 . Although magnetic stripe  410  is shown to occupy less than the entire space of pocket  420 , it is understood that magnetic stripe  410  may occupy the entire space of pocket  420 . In some embodiments, an adhesive layer may not be used. Magnetic stripe  410  may be placed within pocket  420  and be securely held by card inlay  411  and card housing  412  when they are attached to each other to form card frame  405 . It is understood that when an adhesive layer is not used, magnetic stripe  410  may occupy the entire space of pocket  420 , at least in the thickness direction of card frame  405 , such that magnetic stripe  410  is constrained in at least the thickness direction. 
       FIG. 7  illustrates a cross-sectional view of the exemplary transaction card  400  shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments. As shown in  FIG. 7 , pocket  420  may include two portions, a first portion formed in the inner surface of card inlay  411  and a second portion formed in the inner surface of card housing  412 . For example, the inner surface of card inlay  411  may have a recessed portion defining the first portion of pocket  420 , and the inner surface of card housing  412  may have a corresponding recessed portion defining the second portion of pocket  420 . Magnetic stripe  410  may be disposed within pocket  420  formed in both card inlay  411  and card housing  412 . Although  FIG. 7  shows that magnetic stripe  410  occupies less than the entire space of pocket  420 , it is understood that in other embodiments, magnetic stripe  410  may occupy the entire space of pocket  420 . As shown in  FIG. 7 , magnetic stripe  410  may be affixed to the inner surface of card inlay  411  through an adhesive layer (not shown), and when card inlay  411  and card housing  412  are assembled together, magnetic stripe  410  is disposed within both the first and second portions of pocket  420 . It is understood that in other embodiments, magnetic stripe  410  may be affixed to the inner surface of card housing  412 , and when card inlay  411  and card housing  412  are assembled together, magnetic stripe  410  is positioned within both the first and second portions of pocket  420 . In some embodiments, an adhesive layer may not be used. Magnetic stripe  410  may be placed within the first or the second portion of pocket  420  before card inlay  411  and card housing  412  are assembled to form card frame  405 . When card frame  405  is formed, magnetic stripe  410  may be securely held by card inlay  411  and card housing  412 . It is understood that when an adhesive layer is not used, magnetic stripe  410  may occupy the entire space of pocket  420 , at least in the thickness direction of card frame  405 , such that magnetic stripe  410  is constrained in at least the thickness direction. 
       FIGS. 8A and 8B  show cross-sectional views of exemplary transaction card  400  shown in  FIG. 4  taken along line A-A of  FIG. 4 , consistent with different disclosed embodiments. As shown in  FIGS. 8A and 8B , transaction card  400  may have a curved card frame. That is, surfaces of card frame  405  may be curved instead of being flat. As shown in  FIGS. 8A and 8B , magnetic stripe  410  may also have a curved shape. For simplicity,  FIGS. 8A and 8B  do not show pocket  420  separately. It is understood that magnetic stripe  410  may be disposed within pocket  420 , as shown in other embodiments disclosed herein. Magnetic stripe  410  may occupy a portion of pocket  420 , or the entire space of pocket  420 . Curved magnetic stripe  410  may follow the same curvature as the curved surfaces (or one of the curved surfaces) of card frame  405 . In some embodiments, curved magnetic stripe  410  may have a curve that is different from the curve of card frame  405 . As shown in  FIGS. 8A and 8B , magnetic stripe  410  may be disposed on the inner surface of card inlay  411  or card housing  412 . As discussed above, magnetic stripe  410  may be disposed within pocket  420 , which may be provided on an inner surface of card inlay  411 , card housing  412 , or both. It is understood that the embodiments shown in  FIGS. 8A and 8B  can be combined with other embodiments, such as those shown in  FIGS. 2-7 . 
       FIGS. 9A and 9B  show top views of exemplary transaction card  400  consistent with the disclosed embodiments. Magnetic stripe  410  is disposed inside card frame  405  and may or may not be visible. For example, when the material for forming card inlay  411  and/or card housing  412  is not transparent or translucent, magnetic stripe  410  disposed inside card frame  405  may not be visible from outside. When the material for forming card inlay  411  and/or card housing  412  is transparent or translucent, magnetic stripe  410  may be visible from outside. When a transparent or translucent material is used for forming a portion of card inlay  411  and/or card housing  412  at a location corresponding to the location of magnetic stripe  410 , magnetic stripe  410  may be visible from outside. 
     In the embodiments in which magnetic stripe  410  is not visible, a stripe indicator  430  may be provided on an exterior surface (e.g., front or back surface) of card frame  405  to indicate to a user the location of magnetic stripe  410  inside card frame  405 . Stripe indicator  430  may be provided on the exterior surface at the same location with respect to the edges of card frame  405  as magnetic stripe  410 . In other words, stripe indicator  430  may be located on the exterior surface at a location above magnetic stripe  410  in the thickness dimension of card frame  405 . Stripe indicator  430  may include various indicators for indicating the location of magnetic stripe  410 . For example, stripe indicator  430  may appear differently than other portions of the exterior surface of card frame  405  to indicate the location of magnetic stripe  410 . In one embodiment, stripe indicator  430  may have a color that is different from the color of the other portions of the exterior surface. In another embodiment, stripe indicator  430  may have a printed pattern that is not present in the other portions of the exterior surface. In some embodiments, stripe indicator  430  may include a material that feels or looks differently than the material included in the other portions of card frame  405 . In some embodiments, stripe indicator  430  may use icons, texts, or other suitable ornamental items to indicate the location of magnetic stripe  410 . 
     Other aesthetic techniques known in the art may also be used in stripe indicator  430  to indicate the location of magnetic stripe  410  inside card frame  405 . For example, stripe indicator  430  may be printed with an ink having a different finish than the other portions of the exterior surface of card frame  405 . In one embodiment, stripe indicator  430  may be printed with a matte finish while the other portions of the exterior surface may be printed with a glossy finish. Other aesthetic techniques, such as heat transfer (e.g., stripe indicator  430  having a different thermo transfer capability than other portions of card frame  405 ), may also be used to indicate the location of the internal magnetic stripe  410 . It is understood that the embodiments shown in  FIGS. 9A and 9B  can be combined with other embodiments disclosed herein, such as those disclosed in  FIGS. 2-8 . 
     Different materials may be used to construct card frame  405  including card inlay  411  and card housing  412 . Suitable materials include TPE (thermoplastic elastomer) resins and mixture of TPE and another material, such as TPE-PBT resins (thermoplastic elastomer mixed with polybutylene terephthalate), TPE mixed with acetal homopolymers, etc. Acetal homopolymers may include commercially available acetal homopolymers, such as Delrin® made by DuPont®. Other or different commercially available homopolymers may be used, if desired. 
     Thermoplastic elastomers (TPEs) may include of copolymers and/or mixtures of polymers that exhibit properties of thermoplastics and elastomeric materials. For example, the resin used to form card frame  405  may include a polyester elastomer, a block copolymer, a thermoplastic olefin, an elastomeric alloy, a thermoplastic polyurethane, a thermoplastic copolyester, or a thermoplastic polyamide. 
     In some embodiments, the resin mixture used to form card frame  405  includes a polyester elastomer, such as a commercially available polyester elastomer. Commercially available polyester elastomers suitable for use in forming card frame  405  with a soft touch feel may include Hytrel® 8238 made by DuPont®. Other suitable polyester elastomers that are commercially available may include Hytrel® 7246 made by DuPont®. While some commercially available TPEs are mentioned specifically herein, other TPEs may be used in various embodiments. 
     The resin mixture for forming card frame  405  may include materials for increasing the strength and durability of card frame  405 . For example, the resin mixture for forming card frame  405  may include polybutylene terephthalate (PBT) or be mixed with materials that include PBT. Suitable PBTs or materials that include PBT may include commercially available PBTs, such as Crastin® made by DuPont®. Other or different commercially available PBTs or materials that contain PBT may be used, if desired. As used herein, reference to PBT should be understood to include materials containing PBT. 
     The PBT used in the resin mixture for forming card frame  405  may have a flexural modulus in the range of 1600-8500 MPa. For example, the PBT used in the resin mixture for forming card frame  405  may have a flexural modulus in the range of 1600-8500 MPa, 2000-8000 MPa, 2500-7500 MPa, 3000-7000 MPA, 3500-6500 MPa, 4000-6000 MPa, 4500-5500 MPa, or 4750-5250 MPa. Depending on the selected PBT and/or other materials used in the resin for forming card frame  405 , the selected PBT may have a different flexural modulus, if desired. 
     The PBT used in the resin mixture for forming card frame  405  may also have a flexural strength in the range of 50-200 MPa. For example, the PBT used to for card frame  405  may have a flexural strength in the range of 50-200 MPa, 75-175 MPa, 100-150 MPa, or 120-130 MPa. Depending on the selected PBT and/or other materials used in the resin for forming card frame  405 , the selected PBT may have a different flexural strength, if desired. 
     The resin mixture for forming card frame  405  may include a mixture of TPE and one or more of acetal homopolymer and PBT. The resin mixture forming card frame  405  may include a mixture having a 50:50 ratio, a 60:40 ratio, a 40:60 ratio, a 70:30 ratio, a 30:70 ratio, or another ratio of TPE to one or more of acetal homopolymer and PBT. The resin mixture for forming card frame  405  may include other or additional materials, if desired. 
     Consistent with the disclosed embodiments, high output magnetic stripes can be used as internal magnetic stripe  410  to reduce the failure rate and meet the ISO specification. For example, the failure rate of a high output internal magnetic stripe  410  consistent with the disclosed embodiments may not exceed 1.5%, 2%, or 3%. Magnetic stripes used in traditional cards may not meet the ISO specification on the card reading failure rate because they are typically low output magnetic stripes. 
       FIG. 10  is a flowchart illustrating an exemplary method  1000  for manufacturing a transaction card, consistent with the disclosed embodiments. Method  1000  may be performed by one or more machines or devices, such as an injection molding device, a CNC machining device, and other automated manufacturing devices, which may be controlled by at least one processor. The processor may be specially programmed to operate one or more manufacturing devices to perform the disclosed methods for manufacturing transaction card  400 . 
     As shown in  FIG. 10 , method  1000  may include forming a card inlay (step  1005 ). For example, an injection molding device may form card inlay  411 . Method  1000  may also include forming a card housing (step  1010 ). For example, the injection molding device may form card housing  412 . 
     Method  1000  may include forming a pocket in at least one of the card inlay or the card housing (step  1015 ). For example, the injection molding device may form pocket  420  in an inner surface of either card inlay  411 , card housing  412 , or both (by forming a first portion of pocket  420  in the inner surface of card inlay  411  and a second portion of pocket  420  in the inner surface of card housing  412 ). When pocket  420  is formed in either card inlay  411  or card housing  412 , pocket  420  may be formed in the same injection molding process as card inlay  411  or card housing  412 . When pocket  420  is formed by a first portion in card inlay  411  and a second portion in card housing  412 , the first portion may be formed together with card inlay  411  in the same injection molding process. The second portion may be formed together with card housing  412  in the same injection molding process. In some embodiments, after card inlay  411  and/or card housing  412  are formed, a subsequent CNC machining device may form pocket  420  in an inner surface of card inlay  411 , card housing  412 , or both. Pocket  420  may be formed in the inner surface of card inlay  411  and/or card housing  412  by removing (through the CNC machining process) a portion of card inlay  411  and/or card housing  412  from their inner surfaces. 
     Method  1000  may include positioning a magnetic stripe on at least one of an inner surface of the card inlay or an inner surface of the card housing (step  1020 ). For example, magnetic stripe  410  may be affixed (e.g., via an adhesive layer) to an inner surface of card inlay  411  or an inner surface of card housing  412  at a location corresponding to the location of pocket  420 . In some embodiment, an adhesive layer may not be used. Magnetic stripe  410  may be disposed within pocket  420  and securely held by card inlay  411  and card housing  412  when card inlay  411  and card housing  412  are attached to each other. 
     Method  1000  may also include attaching the card inlay to the card housing to form a card frame (step  1025 ). When the card frame is formed, the magnetic stripe is disposed inside the card frame between the card inlay and the card housing. 
     In some embodiments, the method may further include forming another pocket in card inlay  411  and/or card housing  412  for embedding a microchip. In some embodiments, the method may further include printing card information on a surface of the card inlay and/or card housing. The card information may include, but is not limited to, card number, expiration date of the card, VISA/Mastercard logo, hologram, card issuing company logo, customer/card holder&#39;s name, a photo of the card holder, and a signature of the card holder. 
     While illustrative embodiments have been described herein, the scope includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations or alterations based on the present disclosure. For example, the order of the steps of the above exemplary method may be rearranged in any preferred or suitable order, or any step may be removed or added. 
     The elements in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. It is intended, therefore, that the specification and examples be considered as example only, with a true scope and spirit being indicated by the following claims and their full scope of equivalents.