Patent Description:
Typical transaction cards are made from thermoplastic materials, such as polyvinyl chloride (PVC) and polyethylene terephthalate (PET). However, these transaction cards are susceptible to being damaged or destroyed if exposed to damaging environments. For example, transaction cards may be damaged if left exposed to the elements for an extended period of time. Moisture and/or sunlight may break down the chemical bonds within the polymers of typical transaction cards, such that transaction cards left exposed to moisture and sunlight may become warped, cracked and/or unusable. In addition, thermoplastic transaction cards may be easily bent or may be broken or cut, thereby damaging the transaction card and rendering it unusable.

To reduce some of the problems with the thermoplastic materials, transaction cards started to be fabricated with different types of metal and/or metal alloys to provide more durability and a higher status symbol. One issuer such as American Express® may issue millions of such metal cards to account holders each year. However, metal transaction cards may impact the functionality of integrated circuits with antennas. In particular, the metal card body may reduce or prevent the distribution of EM signals from the EMV chip through the metal card body. To help facilitate the distribution of EM signals from the EMV chip through the metal card body, metal transaction cards have included a slit in the card body. For example, a continuous <NUM> degree cut that is about <NUM> microns wide and through the card body, from the edge of the card to about ¾ of an inch into the card and through the chip milling area. The continuous <NUM> degree cut may be a straight line cut, a stepped cut or a squiggle cut.

However, such a cut tends to be a weak point in the planar surface. In particular, transaction cards are often pulled, bent, twisted and/or torqued in different ways (e.g., when removing from a wallet, inserting into an ATM, etc.). Such actions often put strain on the cut area causing the cut to further separate, the cut to extend further into the card and/or the part of the card next to the cut to crack. In particular, opposite pressure on either edge of the cut may split the card or break the EMV chip.

US patent application with publication number <CIT> describes coupling frames for radio frequency identification (RFID) devices. A transponder chip module is described which comprises an RFID chip, optionally contact pads, a module antenna, and a coupling frame, all on a common substrate or module tape. The coupling frame may be in the form of a conductive layer having an outer edge and a slit or non-conductive stripe extending from the outer edge to an inner position thereof which may be a central opening.

PCT patent application with publication number <CIT> describes smart cards with metal layer(s) and methods of manufacturing the smartcards. <CIT> describes that one or more metal layers of a smartcard stackup may be provided with slits overlapping at least a portion of a module antenna in an associated transponder chip module disposed in the smartcard so that the metal layer functions as a coupling frame.

US patent application with publication number <CIT> describes a manufacturing method for an integrated circuit card. The electronic card comprises an electrically insulating card support provided with a cavity for accommodating an integrated circuit and, on one surface, with metal contact pads which are electrically connected to contacts of the integrated circuit.

Therefore, a need exists for a transaction card that has strength, durability and withstands exposure to the elements, while also avoiding or minimizing the impact of the distribution of EM signals from the EMV chip through the metal card body.

Aspects of the present invention are defined by the independent claims below to which reference should now be made. Optional features are defined by the dependent claims.

In various embodiments, the disclosure includes a transaction card comprising a card body having a slot. A first portion of the slot is formed at a first angle relative to a plane of the card body, and a third portion of the slot is formed at a third angle relative to the plane of the card body. The slot may include a second portion having a second angle. The second portion may connect the first portion and the third portion. The first portion, the second portion and the third portion may form a step shape. The second portion may be perpendicular to the first portion and the third portion. The first angle may be about <NUM> degrees with respect to a plane of the card body and the third angle may about <NUM> degrees with respect to a plane of the card body. In other embodiments, the first angle may be about <NUM> degrees with respect to a plane of the card body and the third angle is about <NUM> degrees with respect to a plane of the card body. At least a portion of the third portion of the slot may extend under an EMV chip. The first portion begins at an edge of the card body. An EMV chip may be within a pocket in the card body and the pocket may include an aperture through the card body. The card body may also include at least one of a diamond like carbon (DLC) coating, ceramic, PVD, Ink, PVC laminate or other materials over at least a portion of the card body. The card body may include a metallic material comprising at least one of titanium, aluminum, or stainless steel. The card body may also include a marking, perforation, etching, relief or finishing features.

In various embodiments, a method of fabricating a card body may comprise positioning the card body at a first angle with respect to a cutter; creating a first portion of a slot in the card body at the first angle by at least one of translating the card body across the cutter or translating the cutter across the card body; stopping the translating of the card body; rotating at least one of the card body or the cutter to a third angle to create a second portion of the slot; and creating a third portion of the slot in the card body at the third angle by at least one of translating the card body across the cutter or translating the cutter across the card body. The translating the transaction card across the cutter may include creating a third portion of the slot that ends underneath an EMV chip.

Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the various embodiments and from the drawings.

A more complete understanding of the present disclosure, however, may be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.

<FIG> illustrates a transaction card <NUM> showing primary surface <NUM>. The transaction card <NUM> may be composed of card body <NUM> which may comprise any material disclosed herein. The transaction card <NUM> includes a width <NUM> relative to height <NUM>. Primary surface <NUM> and secondary surface <NUM> may include a DLC coating and various features that are produced through marking, finishing, etching, and/or perforation, as described herein. Primary surface <NUM> may comprise one or more of a matte surface and a glossy surface. In various embodiments, primary surface <NUM> may be polished to a glossy, highly reflective surface. Finishing may be used to transform a portion of the glossy surface to a matte finish.

In various embodiments, and with reference to <FIG>, fabricating the transaction card <NUM> may include creating different layers of the transaction card <NUM>. The overall transaction card <NUM> may include various layers including, for example, one or more of a diamond clear coating <NUM>, raised letter printing <NUM>, black ceramic coating <NUM>, card body <NUM> comprised of a stainless steel inlay with antenna, a glue lam <NUM>, a black PVC print layer <NUM> and a clear laminate <NUM> with a magnetic stripe <NUM> or signature panel (e.g., milled within the laminate).

As shown in <FIG>, <FIG>, in various embodiments, any layer of the transaction card <NUM> (e.g., card body <NUM>) may include an angled slot <NUM> having a first portion <NUM>, a second portion <NUM> and a third portion <NUM> in the card body <NUM>. The slot <NUM> may be, for example, about <NUM> microns wide (a typical transaction card thickness <NUM> is about <NUM> (+/-<NUM>%) microns). Slot <NUM> may pass through the entire thickness <NUM> of card body <NUM>, though in various embodiments slot <NUM> may be a score or channel within card body <NUM>. The angled slot <NUM> may be in the form of a "French cleat". In that regard, the transaction card includes multiple slots <NUM> (or multiple portions of a slot <NUM>) formed from different angles. As such, the angled slot <NUM> may prevent or minimize separation. In particular, the angled slot <NUM> may prevent or minimize separation when pressure is applied to the card from opposite sides. If just one angled slot <NUM> is used (e.g., just the first portion <NUM> or just the third portion <NUM>), reverse pressure points on either side of the slot <NUM> may still split the card and/or break the EMV chip <NUM>.

As shown in <FIG>, the slot <NUM> may start at an edge of the card body <NUM> and end below the EMV chip <NUM>. In particular, the third portion <NUM> of the slot <NUM> may end at a far edge of an aperture <NUM> within a pocket <NUM> (the far aperture edge is the aperture edge farthest from the card edge <NUM> where the slot <NUM> starts). In particular, the card body <NUM> may include a pocket <NUM> that houses the EMV chip <NUM>. Pocket <NUM> may be created by any device or process that may form the pocket such as by milling, laser cutting, chemical etching, whittling, etc. The pocket <NUM> may be centered at about <NUM> inches from the closer side of the card and <NUM> inches from the top of the card. The pocket <NUM> may include an aperture <NUM> in the center of the pocket <NUM>. The pocket <NUM> includes a recessed ledge <NUM> within the pocket <NUM> and the recessed ledge <NUM> surrounds the aperture <NUM>. Thus, the outer rim of the EMV chip <NUM> may rest on the recessed ledge <NUM>, while the center of the EMV chip <NUM> is suspended over the aperture <NUM>.

As shown in <FIG> and <FIG>, the angled slot <NUM> may communicate with the antenna in the EMV chip <NUM>. The EMV standard governs how payment cards and point of sale (POS) terminals interact to facilitate purchases and withdrawals in a fast and secure manner. The EMV standard also enables verifications of payments. The EMV chip <NUM> uses capacitive coupling and/or inductive coupling to facilitate an exchange of data communication and energy with a contactless reader. EMV chip <NUM> also drives active elements such as, for example, for integrating into payment objects and identification objects. As such, when the transaction card is waved over a POS terminal, the POS terminal may send out an EM field with EM energy. The slot <NUM> may focus energy above and/or below the slot <NUM>. The card body <NUM> that is metal absorbs the EM energy and the slot <NUM> acts as a contactless antenna, so the EM energy is focused into the slot <NUM>. As discussed above, the slot <NUM> overlaps with the EMV chip <NUM>, so in an EM field, the surface current around the slot <NUM> may provide the power delivery to the EMV chip <NUM> by coupling the EM energy to the inductive coupling contact pad that includes a module antenna of the EMV chip <NUM>. The coupling may be a reactive coupling that includes a combination of capacitive and inductive coupling.

In various embodiments, each portion may be formed at any angle and be any length. As shown in <FIG>, first portion <NUM> of slot <NUM> may be in a range of between about <NUM> degrees to about <NUM> degrees with respect to the plane of the card body. For example, first portion may be at an about <NUM> degree angle from the plane of the card. The length of first portion <NUM> may be in a range of between about <NUM>-<NUM> inches into the card from an edge <NUM> of the card. For example, the length may be about <NUM>/<NUM>, ¼ or <NUM>/<NUM> inches in various embodiments. However, the length of the first portion <NUM> may vary depending on the size of the contact pad and pocket <NUM>. The second portion <NUM> is formed substantially perpendicular to the first portion <NUM> based on rotating the card about <NUM> degrees. The second portion may be formed with an about <NUM> degree angle from the plane of the card. The third portion <NUM> of the slot <NUM> may be in a range of between about <NUM> degrees and about <NUM> degrees with respect to the plane of the card body. For example, third portion <NUM> may be at an opposite about <NUM> degree angle from the plane of the card (i.e., <NUM> degree angle from the original plane of the card). Third portion <NUM> may be in a range of between about <NUM> inches to about <NUM> inches in length. For example, the length of the third portion <NUM> may be about <NUM> inches. This may leave about <NUM> microns of overlap in each direction (i.e., the horizontal distance between the top cut of the slot <NUM> to the bottom cut of the slot <NUM>), with a length within the angled slot <NUM> of about <NUM> microns (i.e., the angled distance between the top cut of the slot <NUM> to the bottom cut of the slot <NUM>).

In other embodiments, the first portion <NUM> of the slot <NUM> may be at an about <NUM> degree angle from the plane of the card. The third portion <NUM> of the slot <NUM> may be about <NUM> inches in length and may be at an opposite about <NUM> degree angle from the plane of the card (i.e., <NUM> degree angle). This may leave about <NUM> microns of overlap in each direction, with a length of the angled slot <NUM> of about <NUM> microns.

The slot <NUM> may be formed into the card. In various embodiments, the slot <NUM> may be formed by cutting the slot <NUM> out of the card body <NUM> (e.g., laser cutter). The card body <NUM> may be pushed through the cutter or the cutter may move across the card body <NUM>. The cutter may be mounted to a 3D robot arm, to allow the cutter to move across the card body <NUM>. A jig may translate the card body <NUM> through a perpendicular cutter (e.g., laser beam). The card body <NUM> may move a little more than about <NUM> inches when forming all of the first portion <NUM>, second portion <NUM> and third portion <NUM> of the slot <NUM>. As set forth in <FIG>, the card body is positioned at a first angle with respect to the cutter (step <NUM>). The device creates a first portion of a slot in the card body at the first angle by at least one of translating the card body across the cutter or translating the cutter across the card body (step <NUM>). After completing the first portion <NUM>, the card body <NUM> or cutter is no longer translated (step <NUM>), then the card body <NUM> or cutter may be rotated about <NUM> degrees (step <NUM>). Such rotation causes a second portion <NUM> of the slot <NUM> to be formed substantially perpendicular to the first portion <NUM>. The card body <NUM> or cutter is then translated again to form the third portion <NUM> (step <NUM>).

In various embodiments, the fabrication of the slot <NUM> may completed with a jig (e.g., laser jig), as set forth in <FIG>. In particular, the card may be placed on mounting device <NUM> of a jig that moves the card through a perpendicular cutter <NUM> (e.g., laser cutter) or cutter <NUM> translates over the jig. The mounting device <NUM> may include a lifting table <NUM> that includes a hinge <NUM> on one end of the lifting table <NUM> and a guide handle <NUM> on the other end of the lifting table <NUM>. A card locking mechanism <NUM> holds the card against a front face of the lifting table <NUM>. The hinge <NUM> rotatably connects the lifting table <NUM> to an about <NUM> degree block <NUM>. The <NUM> degree block <NUM> is mounted on a slide block <NUM>. The cutter <NUM> may be fixed perpendicular to the mounting device <NUM>, but the lifting table <NUM> may be rotated around its hinge <NUM> from about -<NUM> degrees to about +<NUM> degrees.

In various embodiments, the fabrication of the slot <NUM> may be completed with a robotic arm <NUM>, as set forth in <FIG>. The robotic arm <NUM> may hold the card body <NUM> between cutter <NUM> (e.g., a laser cutter or wire cutter). The cutter <NUM> may be fixed perpendicular to the robotic arm <NUM>. The robotic arm <NUM> moves the card body <NUM> through the cutter <NUM> to form the first portion <NUM> of the slot <NUM> at the about <NUM> degree angle. After cutting the first portion <NUM> of the slot <NUM>, the robotic arm <NUM> does not translate the card, but rotates the card about <NUM> degrees (i.e., from about -<NUM> degrees to about +<NUM> degrees). The rotation of the card body <NUM> below the cutter <NUM> forms the second portion <NUM> of the slot <NUM>. The robotic arm <NUM> then translates the card body <NUM> again to form the third portion <NUM> of the slot <NUM> at the about <NUM> degree angle. In particular, after the rotation is complete, the cutting may proceed about parallel to the first portion <NUM> of the slot <NUM>. The third portion <NUM> of the slot <NUM> may be fabricated by cutting at an opposite about <NUM> degree angle from the plane of the card (i.e., about <NUM> degree angle). The third portion <NUM> of the slot <NUM> may be in a range of between about <NUM> to <NUM> inches and end at a far edge of an aperture within a pocket (the far aperture edge is the aperture edge farthest from the card edge where the slot <NUM> starts).

The slot <NUM> then may be filled with non-conductive filler. The excess filler may then be polished or buffed off the surface (front and back) of the card body <NUM> and off the edges. Filling the slot <NUM> may also include vacuum pulling glue into the slot <NUM> and curing the glue. A DLC or metal coating may be applied to the card body <NUM>. As discussed above with respect to <FIG>, a pocket <NUM> for the EMV chip <NUM> may be milled out of the card. The pocket <NUM> may include an aperture <NUM> in the center of the pocket. The pocket includes a recessed ledge <NUM> within the pocket and the recessed ledge <NUM> surrounds the aperture <NUM>. Thus, the EMV chip <NUM> may rest on the recessed ledge <NUM>, while the center of the EMV chip <NUM> is suspended over the aperture <NUM>.

In various embodiments, multiple slots <NUM> may be formed in a sheet of cards prior to cutting out the individual card bodies. In other embodiments, individual card bodies <NUM> are first cut out of the sheet prior to forming the slot <NUM> in each card body <NUM>. The slots <NUM> are formed in each transaction card. After all of the milling and cutouts are completed on the individual cards, multiple cards are then embedded in PVC in a sheet format on a tray (e.g., <NUM> cards per tray). The multiple cards are maintained in the sheet format with <NUM>-<NUM> tabs per card to lock the card in place. The multiple cards are maintained in a sheet format to allow for more accurate alignments, more accurate registration, easier card art and more efficient printing on the cards. A magnetic stripe <NUM> is mounted onto a non-stick sheet. Glue is used and laminate is melted into the magnetic stripe <NUM> cutout. A computerized number control (CNC) lathe machine is used to cut and polish the magnetic stripes <NUM>. The top and bottom non-stick may easily peel off, and the cards can be popped out.

As used herein, a "transaction card" may include any surface, object, device or any part of a card that includes a slot <NUM>, regardless of the card's ability to conduct a transaction. Slot <NUM> may be within the card body or any other part of the card. A "transaction card" may also include any device that acts as a contactless antenna and/or focuses EM waves. The disclosure may also apply to minimizing or preventing breakage of any surface, object or device. For example, a transaction card may be a charge card, credit card, debit card, awards card, prepaid card, telephone card, smart card, magnetic stripe card, bar code card, transponder, radio frequency card and/or the like. The transaction card may have an associated account number (e.g., embossed, printed, and/or accessed), which cardholders typically present to merchants or use to interact with a machine, as part of a transaction, such as a purchase.

ISO <NUM> stipulates that transaction cards in the "ID-<NUM>" format be <NUM> in width × <NUM> in height × <NUM> in thickness (<NUM>. 370in × <NUM>. 125in × <NUM>. 03in) (as the terms width, height, and thickness are further discussed herein). In various embodiments, transaction cards may be standard-sized (i.e., about <NUM><NUM>/<NUM> inches by about <NUM>¼ inches by about <NUM> inches, and/or those dimensions specified in ISO <NUM> and ISO <NUM>, for example, for an "ID-<NUM>" card) or any other size specified in ISO <NUM> and ISO <NUM> or any other size or configuration still usable as a transaction card or configured to interact with another card or device (e.g., a larger transaction card, small transaction card, reduced size transaction card, foldable transaction card, the card being part of another device, the card being removed from another device). Moreover, the transaction card may have a magnetic stripe <NUM>, an embedded EMV chip <NUM>, a signature panel, a holographic image, and/or any feature typically contained on or within a transaction card. Various foldable cards and/or transaction cards of non-traditional size may be used as the transaction card in various embodiments.

A card body <NUM> may refer to a material in any shape or thickness. The card body <NUM> may be shaped substantially as a transaction card and/or a layer of a transaction card. In that regard, the card body may be generally sized as a transaction card though it may not meet ISO <NUM> and/or <NUM> dimensions. A layer of a transaction card may refer to a material that has the length and width (as defined herein) substantially near the ISO <NUM> and/or <NUM> specified dimensions but has a thickness (as defined herein) less than the ISO <NUM> and/or <NUM> specified dimensions. In that regard, a transaction card <NUM> may comprise a layer of metal that is, in various embodiments, bonded, laminated and/or otherwise coupled to another layer (or a transaction card having a metal layer and another layer such as a ceramic layer). In various embodiments, a metallic card body may have the width and height of an ID-<NUM> card as set forth in ISO <NUM> and ISO <NUM>, but may have a thickness that is less than the thickness of an ID-<NUM> card as set forth in ISO <NUM> and ISO <NUM>. For example, a metallic card body may have a thickness of less than <NUM> in. and/or less than <NUM> in.

The card body <NUM> may be polished and/or buffed to a glossy, highly reflective finish. The finishes may include, for example, ceramic, PVD, DLC, ink, chemical process or any other finishing technique. In various embodiments, one or more cutters or lasers may be used to alter the card body. For example, a laser may emit a focused beam of light having a given power output. Thus, a laser directed at a surface may have varying effects on the surface based upon the power output of the laser and the duration of exposure. Lasers may emit a light over a small area, providing the ability for precision works. Moreover, lasers may be accurately and precisely controlled via electronic control systems for manufacturing ease. A typical laser may be obtained from Virtek Laser Solutions, Inc. In various embodiments, a <NUM>, 25W diode pumped YVO4 laser may be used.

The effect a laser may have on a metal material depends in part on the power output of the laser and the duration of exposure. For example, exposure for a short time to a low power laser may alter the surface characteristics of a metal material, for example, changing a glossy finished surface to a matte finish (i.e., one that is not as reflective to visible light). In contrast, exposure to a high power output laser for a first duration, or a lower power output laser for a second duration that is longer than the first duration, may cause a perforation of the metal material. In that regard, various laser processes may be characterized by their effect on a metal material. These various techniques may be applied, in various embodiments, in the manufacture of a card body or the entire transaction card. Lasers can provide marking of metal materials at depths of as low as about <NUM> inches. Though lasers may have various power outputs, for purposes of explanation, various laser processes may be characterized by the total power during the exposure to a metal material. Stated another way, the total power of laser exposure to a surface may be thought of as the amount of laser energy applied per unit time of exposure.

With respect to <FIG>, card body <NUM> may comprise pocket <NUM>. Pocket <NUM> may comprise an indentation or other depression that is offset from primary surface <NUM>. EMV chip <NUM> is disposed in pocket <NUM>. The position of EMV chip <NUM> on the card body <NUM> may be standardized by industry practice (for example, ISO <NUM>). EMV chip <NUM> may include an integrated antenna so that EMV chip <NUM> may facilitate wireless transactions. EMV chip <NUM> may comprise any suitable recordable media, for example, an integrated circuit. EMV chip <NUM> may comply with one or more industry standards such as ISO <NUM> and ISO <NUM> to provide "smartcard" functionality to transaction card <NUM>. In that regard, EMV chip <NUM> may aid in the facilitation of financial transactions. Many jurisdictions may now prefer a EMV chip <NUM> in transaction cards. EMV chip <NUM> may be disposed onto a card body in a variety of ways. Pocket <NUM> may be formed so that when EMV chip <NUM> is disposed therein, a surface of EMV chip <NUM> will be flush or substantially flush with primary surface <NUM>. An adhesive may be disposed in the pocket <NUM> or on the EMV chip <NUM> prior to positioning an EMV chip <NUM> into a pocket <NUM> in card body <NUM>. Any suitable adhesive may be used. For example, ABLEBOND <NUM>-1T1N1 may be used for this purpose. Further, in various embodiments, an insulating material may be disposed in the card body <NUM> pocket <NUM> to be positioned between the EMV chip <NUM> and the card body <NUM> so as to electrically insulate the EMV chip <NUM> and the card body. An adhesive may act as an insulating material. Any insulator may be used for this purpose.

In various embodiments, as set forth in <FIG>, card body <NUM> may comprise any material. In various embodiments, the material for the card body may be a metallic material comprising any suitable metal and/or metal alloy, including titanium, titanium alloy, aluminum, aluminum alloy stainless steel, tin, zinc, copper, nickel, chromium, tungsten, brass and/or nickel/chromium alloys.

Card body <NUM> may have card backer applied to card body <NUM> comprised of a laminate, print layer and/or coating. The card backer may include any of the surfaces disclosed in <FIG> such as, for example, a diamond clear coating <NUM>, raised letter printing <NUM>, black ceramic coating <NUM>, a glue lam <NUM>, a black PVC print layer <NUM> and a clear laminate <NUM> with a magnetic stripe <NUM> or signature panel (e.g., milled within the laminate). A card backer may refer to a transaction card shaped material in any size, shape or thickness. The card backer may be shaped substantially as a transaction card and/or a layer of a transaction card. In that regard, the card backer may be generally sized as a transaction card though it may not meet ISO <NUM> and/or <NUM> dimensions. A card backer may have the length and width (as defined herein) substantially near the ISO <NUM> and/or <NUM> specified dimensions but has a thickness (as defined herein) less than the ISO <NUM> and/or <NUM> specified dimensions. In that regard, a transaction card, according to various embodiments, may comprise a card backer coupled to (by bonding, lamination, and/or other suitable method) a card body. In various embodiments, a card backer may have the width and height of an ID-<NUM> card as set forth in ISO <NUM> and ISO <NUM>, but may have a thickness that is less than the thickness of an ID-<NUM> card as set forth in ISO <NUM> and ISO <NUM>. For example, a card backer may have a thickness of less than <NUM> in. , less than <NUM> in. , <NUM> in. , less than. <NUM>, and between <NUM> inches and <NUM> inches.

In various embodiments, a metallic card body may be coated with a protective coating. The coating may be deposited via physical vapor deposition (PVD). In various embodiments, the body may be coated with a protective coating such as a diamond like carbon (DLC) coating. A DLC coating may be generally amorphous, though portions of a DLC coating may have a crystalline structure. For example, a DLC coating may comprise a mixture of forms of carbon, including graphite and diamond. In that regard, carbon in a DLC coating may contain hybridized carbon. A DLC coating may comprise a carbon composition that exhibits high hardness, corrosion resistance, low coefficient of friction (~<NUM> to <NUM>), and high electrical resistivity. A DLC coating may be between <NUM> micron and <NUM> microns thick, between <NUM> microns and <NUM> microns thick, and between <NUM> microns and <NUM> microns thick. A DLC coating may be applied by PVD process, for example, cathodic arc PVD, sputtering, or plasma assisted chemical vapor deposition (CVD).

In various embodiments, a metal-containing transaction card may have a metallic card body and a DLC coating that may provide improved corrosion resistance relative to metallic transaction cards without a DLC coating.

Secondary surface <NUM> may comprise a feature or marking. Feature may include account indicia such as an account number, an accountholder's name, a loyalty notation (e.g., "Member Since <NUM>"), an expiration date, a signature, a brand name, or other indicia such as legal notices, regulatory compliance messages, phone numbers, URLs, email addresses, trademarks, pictures, graphics, bar codes, CCID code or any alphanumeric characters.

As used herein, "finishing" may refer any device or process (e.g., application of a laser to a surface or CNC machining) to remove and/or disrupt a glossy and/or highly reflective finish. For example, laser finishing may impart a matte finish on a metal material surface.

As used herein, "marking" may refer to any device or process (e.g., application of a laser to a surface or CNC machining) imparts a visible disruption to the surface. For example, removing a portion of material from the surface of the card body. In various embodiments, account indicia such as an account number, an accountholder's name, a loyalty notation (e.g., "Member Since <NUM>"), an expiration date, a signature, a brand name, or other indicia such as legal notices, regulatory compliance messages, phone numbers, URLs, email addresses, trademarks, pictures, graphics, bar codes, CCID code or any alphanumeric characters may be marked onto a surface. For example, laser marking may impart visible features to a metal material surface such as readable text onto a metal material surface. Laser marking involves the application of more total power from a laser than laser finishing.

As used herein, "etching" may refer any device or process (e.g., application of a laser to a surface or CNC machining) that imparts an indentation to the surface. In particular, etching may be used to impart various graphic features onto a surface of a card body. In various embodiments, a logo, a decorative border, a brand name, and/or other features may be etched onto a surface. For example, laser etching may remove a portion of metal material from a metal material surface. In that regard, laser marking may impart visible features to a metal material surface that have a palpable depth. Laser etching involves the application of more total power from a laser than laser marking.

As used herein, "perforation" may refer any device or process for (e.g., application of a laser to a surface or CNC machining) to bore a hole completely through the card body. For example, perforation may be used to impart various graphic features onto a card body. In various embodiments, a logo and/or other features may be formed onto a card body. For example, laser perforation may completely remove metal material from a metal material surface, leaving a through hole. In that regard, laser perforation may impart visible features to a metal material surface that traverse a thickness (as defined herein) of a card body. Laser perforation involves the application of more total power from a laser than laser etching. Laser cutting may be performed with similar laser parameters as laser perforation, but laser cutting may be used to remove metal material in any suitable manner.

Marked feature <NUM> is disposed on primary surface <NUM>. Marked feature may be produced by laser marking, as discussed above. In various embodiments, marked feature may include account indicia such as an account number, an accountholder's name, a loyalty notation (e.g., "Member Since <NUM>"), an expiration date, a signature, a brand name, or other indicia such as legal notices, regulatory compliance messages, phone numbers, URLs, email addresses, trademarks, pictures, graphics, bar codes, CCID code or any alphanumeric characters.

Etched feature <NUM> is disposed on primary surface <NUM>. Etched feature may be produced by laser etching, as discussed above. In various embodiments, etched feature may include a logo, and/or a decorative feature such as a border, though other patterns are contemplated herein.

Secondary surface <NUM> may comprise fill panel <NUM>. Fill panel <NUM> may comprise a metal material, for example, the same metal material of card body <NUM>. Fill panel <NUM> may have thickness from about <NUM> in to about <NUM> in, about <NUM> in to about <NUM> in and/or about <NUM> in, wherein the term about may refer to +/- <NUM> in. Fill panel <NUM> may be coupled to a card backer by an adhesive or other suitable coupling method.

Fill panel <NUM> may comprise a gloss/matte feature. A gloss/matte feature may comprise a feature that comprises a gloss portion and matte portion. Together, gloss portion and matte portion may be configured to display account indicia such as an account number, an accountholder's name, a loyalty notation (e.g., "Member Since <NUM>"), an expiration date, a signature, a brand name, or other indicia such as legal notices, regulatory compliance messages, phone numbers, URLs, email addresses, trademarks, pictures, graphics, bar codes, CCID code or any alphanumeric characters. In that regard, alphanumeric characters may be formed as gloss portion against background of matte portion.

A magnetic stripe <NUM> may be disposed on secondary surface <NUM>. Magnetic stripe <NUM> may comprise any suitable recordable media. Magnetic stripe <NUM> may be encoded via any encoding processes commonly used to encode the transaction cards. Specifically, either or both of the recordable media, such as the magnetic stripe <NUM> and/or the EMV chip <NUM>, may be encoded to provide transaction card <NUM> with information beneficial to facilitate a financial transaction. The recordable media may be read via a magnetic stripe reader or a EMV chip <NUM> reader.

Manufacturing a transaction card <NUM> or card body <NUM> (e.g., that contains metal) may include machining, grinding, casting, forging, water jet cutting, die cutting, laser cutting, plasma cutting and stamping, as well as by additive manufacturing techniques. The card body <NUM> may be subject to DLC coating. A DLC coating may be applied by a PVD process, for example, cathodic arc PVD, sputtering, or plasma assisted chemical vapor deposition (CVD). The DLC coating may be applied to primary surface <NUM>, secondary surface <NUM> or both.

The card body <NUM> may be subject to treating. As discussed above, treating may comprise finishing, marking, etching, and perforation. For example, laser finishing, laser marking, laser etching, and laser perforation may be performed on the DLC coated card body <NUM> to create the various features described in connection with those techniques. In various embodiments, a single laser is used for laser treating and set to different total power outputs to accomplish each task. Certain indicia, such as a cardholder's signature, may be captured digitally and used as a digital template to guide the laser in laser marking the cardholder's signature. The DLC coated card body <NUM> may have recordable media applied such as a magnetic stripe <NUM>. A magnetic stripe <NUM> may be disposed on the DLC coated card body using an adhesive or other suitable coupling media. An EMV chip <NUM> may be installed in pocket <NUM>.

Metal-containing transaction cards that are DLC coated have a number of advantages over conventional transaction cards comprised of plastic or metal. DLC coatings may be very hard and thus DLC coated metal-containing transaction cards may resist scratching. DLC coated metal-containing transaction cards may be more resistant to deformation than plastic or metal. Combinations of various features found in DLC coated metal-containing transaction cards described herein may be very difficult to reproduce without costly equipment and know-how. Thus, the risk of fraudulent reproduction of DLC coated metal-containing transaction cards is reduced, thus leading to more security. DLC coated metal-containing transaction cards may further provide a luxurious look and feel, which may be beneficial in the marketplace.

In various embodiments, transaction card <NUM> and related systems (e.g., POS terminal) may be configured with a biometric security system that may be used for providing biometrics as a secondary form of identification. The biometric security system may include a transponder and a reader communicating with the system. The biometric security system also may include a biometric sensor that detects biometric samples and a device for verifying biometric samples. The biometric security system may be configured with one or more biometric scanners, processors and/or systems. A biometric system may include one or more technologies, or any portion thereof, such as, for example, recognition of a biometric. As used herein, a biometric may include a user's voice, fingerprint, facial, ear, signature, vascular patterns, DNA sampling, hand geometry, sound, olfactory, keystroke/typing, iris, retinal or any other biometric relating to recognition based upon any body part, function, system, attribute and/or other characteristic, or any portion thereof.

As shown in <FIG>, an account number <NUM> may appear on the card. An "account number", as used herein, includes any device, code, number, letter, symbol, digital certificate, smart chip, digital signal, analog signal, biometric or other identifier/indicia suitably configured to allow the consumer to interact or communicate with the system, such as, for example, authorization/access code, personal identification number (PIN), Internet code, other identification code, and/or the like which is optionally located on card. The account number may be distributed and stored in any form of plastic, metal, electronic, magnetic, radio frequency, wireless, audio and/or optical device capable of transmitting or downloading data from itself to a second device. A customer account number may be, for example, a sixteen-digit credit card number, although each credit provider has its own numbering system, such as the fifteen-digit numbering system used by American Express. Each company's credit card numbers comply with that company's standardized format such that the company using a sixteen-digit format will generally use four spaced sets of numbers, as represented by the number "<NUM><NUM><NUM><NUM>". The first five to seven digits are reserved for processing purposes and identify the issuing bank, card type and etc. In this example, the last sixteenth digit is used as a sum check for the sixteen-digit number. The intermediary eight-to-ten digits are used to uniquely identify the customer.

In various embodiments, an account number may identify a consumer. In addition, in various embodiments, a consumer may be identified by a variety of identifiers, including, for example, an email address, a telephone number, a cookie id, a radio frequency identifier (RFID), a biometric, a geographic indicator and/or the like. The card may be associated with, have access to or include a rewards account, charge account, credit account, debit account, prepaid account, telephone card, embossed card, smart card, magnetic stripe card, bar code card, transponder, radio frequency card, key card, access card or an associated account. As used herein, any terms similar to "identifier" may be any suitable identifier that uniquely identifies an item. For example, the identifier may be a globally unique identifier ("GUID"). The GUID may be an identifier created and/or implemented under the universally unique identifier standard. Moreover, the GUID may be stored as <NUM>-bit value that can be displayed as <NUM> hexadecimal digits. The identifier may also include a major number, and a minor number. The major number and minor number may each be <NUM> bit integers.

Claim 1:
A transaction card (<NUM>) comprising:
a card body (<NUM>);
an EMV chip (<NUM>) within a pocket (<NUM>) in the card body (<NUM>)
and
a slot (<NUM>) within the card body (<NUM>), wherein a first portion (<NUM>) of the slot (<NUM>) is formed at a first angle relative to a plane of the card body (<NUM>), and wherein a second portion (<NUM>) of the slot (<NUM>) is formed at a second angle relative to the plane of the card body (<NUM>);
wherein the slot (<NUM>) includes a third portion (<NUM>) having a third angle relative to the plane of the card body (<NUM>) characterized in that
the first portion (<NUM>) begins at an edge (<NUM>) of the card body (<NUM>) and the third portion (<NUM>) ends at a far edge of an aperture (<NUM>) of the pocket (<NUM>) which is the aperture edge farthest from the card edge where the slot (<NUM>) starts.