Patent Description:
It relates in particular to the manufacture of smart cards comprising one or more metal sheet(s) or plate(s).

Smart cards can be of the hybrid type (contact and contactless) or purely contactless (without electrical contact block).

Smart cards can have a smart card module comprising on an insulating substrate a radio-frequency transponder comprising the chip and the antenna. These radio-frequency smart card modules are generally inserted in a cavity of the card body.

The invention relates more particularly to bank cards comprising a predominantly metallic body.

There is currently an increased demand from the public for heavy smart cards incorporating metallic materials, the metal of which emerges at the edge or on the card strip. However, this renders the manufacturing methods more complex in order to obtain cards that comply with current smart card standards.

Patent <CIT> describes a smart card module, with an antenna and/or contact pads, which can be incorporated into a card body cavity or which can form an RFID electronic tag. Furthermore, hybrid radio-frequency devices are also known, such as contact and contactless cards comprising a smart card module with contacts incorporated in a card body and connected to an antenna housed in the card body. Furthermore, there are bank cards comprising metal elements such as aluminium, titanium or gold inserted inside the plastic card body or on the outer surface of the card body. The metal provides a heavy feeling to the card which is highly appreciated by the users. It also gives a visible aesthetic appearance which makes it a high-end product for privileged persons.

US Patent Application <CIT> discloses a method for manufacturing a metal card which is capable of allowing metal card antennas to have no interference with a metal sheet by including a processed plastic layer formed on the metal sheet, and an insulating sheet.

The invention aims to address the above-mentioned disadvantages or objectives.

In current manufacturing methods, the position of a plurality of metal inserts sandwiched between two polymer sheets can move during assembly. This generates yield losses during the extraction of each card with an insert by cutting the sandwich structure.

These cards obtained by these methods have a weight of <NUM>, which is insufficient with respect to market demand.

The cards with metal edges which are the subject matter of the invention are assumed to be at least <NUM>. The only possibility, imagined by the inventors, to achieve this objective is to increase the thickness of the metal plate, which necessarily requires printing directly on the metal (rather than on a cover sheet or overlay).

Patent application <CIT> describes a method for locating metal inserts by X-ray in order to extract them easily and with precision. It is also known to interconnect metal inserts with one another in order to maintain their position.

The invention also provides a metal card structure with visible metal edges providing maximum weight, having good radio-frequency performance and which is easy to manufacture.

In particular, the invention relates to a card structure with a radio-frequency RF electronic chip module.

The card can also have a structure that meets constraints of mechanical strength in terms of applicable ISO standards and durability over time. Such cards can conform in particular to the ISO <NUM>, ISO <NUM> and/or ISO/IEC <NUM> standards or equivalents for carrying out contact and/or proximity communication exchanges with a contact or NFC reader.

The invention may consist, according to a preferred embodiment, of placing at least one or preferably several individual metal cards in ISO <NUM> format on an assembly or inlay tray transformed for this purpose.

The tray can be made of metal or a highly temperature-resistant polymer. The tray restricts the movement of the metal insert during the lamination process. Needles or pegs positioned or indexed on the assembly tray also allow printed sheets and the lamination tray to be perfectly indexed or positioned with the metal inserts.

The antenna may preferably be produced by inlaying a conductive wire in a polymer sheet, in particular made of PVC.

Where appropriate, according to a practical embodiment, a relay antenna can be formed (or embedded in) a substrate or block of polymer material or any material permeable to electromagnetic fields, the dimensions of which correspond to that of a recess (or cavity) of a metal plate.

The radio-frequency transponder chip module can be itself mounted on an insert before or after assembling the antenna in the metal plate.

To this end, the invention relates to a method for manufacturing a metal smart card according to claim <NUM>.

The method may include the following other features or steps:.

In general, identical or similar references from one figure to another represent an identical or similar element.

<FIG> illustrates a card structure obtained according to one embodiment of the method for manufacturing a metal smart card 1A comprising a metal insert <NUM>.

The insert <NUM> is here in the form of a metal plate P and has a peripheral edge or contour <NUM> which extends to the peripheral edge <NUM> of the finished card <NUM> (<FIG>). The card also comprises at least one cover sheet <NUM> printed (with a first graphic printing 14i, 14j, <NUM>, 14n) on one of its main faces 1A. It may also preferably comprise a protective film (overlay) 14B above the printed sheet.

The card also preferably comprises a second personalisation graphic printing <NUM> produced directly on the metal insert <NUM> on its face opposite to that bearing the plastic sheet <NUM>.

The card here comprises a metal plate P, for example made of steel, of <NUM> grams or more. The plate P extends to the peripheral edge <NUM> of the card.

The method comprises the following steps according to a preferred embodiment which is illustrated in relation to <FIG> and the various structural <FIG>.

In step <NUM>, (also visible in <FIG>), the method performs the positioning and assembly of a printed 14i support sheet <NUM> and at least one metal insert <NUM> using an assembly tray <NUM>.

The assembly tray <NUM> comprises for this purpose positioning elements <NUM>, <NUM> for positioning the printed 14i support sheet <NUM> and each insert <NUM>. In the example, these are at least two needles or pegs <NUM>, <NUM>.

For its part, the printed support sheet <NUM> preferably comprises a plurality of insert locations <NUM>, a plurality of first printings 14i-14n each corresponding to a graphic printing of a smart card, and positioning marks <NUM>, <NUM> (for example perforations) configured to engage with the positioning elements of the assembly tray.

Each first graphic personalisation 14i-14n can be different from another personalisation (photograph of a user, user name, bank card number, company logo, etc.).

Each first graphic printing 14i, 14j, <NUM>. 14n has preferably been produced by being indexed precisely with respect to marks or perforations <NUM>, <NUM> situated for example at the margin of the support sheet or at a distance from the insert locations 29E.

Each first graphic printing 14i can be carried out in particular by inkjet, screen printing, or any other method known to a person skilled in the art.

In the example, <FIG>, the metal insert is placed in its temporary location <NUM> resting on the tray <NUM>.

According to one feature, the positioning elements <NUM>, <NUM> of the tray can comprise positioning needles perpendicular to the assembly tray; these needles <NUM>, <NUM> pass through the different sheets of the assembly (support <NUM>, compensation <NUM>, protection <NUM>) via indexing perforations <NUM>, <NUM>, <NUM> arranged in each sheet of the assembly at a distance from each insert <NUM>.

Alternatively, the positioning elements of each support sheet <NUM> and of the insert <NUM> can be formed by a frame that centres all of the sheets.

Alternatively, positioning elements such as needles can be arranged in an area of the card intended to be subsequently machined, such as an insert cavity for an integrated circuit module of a smart card or a fingerprint sensor module or other elements flush with the surface of the card. Thus, the advantage is to be able to eliminate the positioning elements (perforation) of the support sheet (located at a distance from the inserts and which engage with those of the insert and/or of the assembly tray). The method thus allows more insert locations on the same support sheet or makes it possible to operate on support sheets in the same format as the inserts. The removal of the perforation can be carried out during the machining of the AM module cavity.

For example, one or more needles may pass through the sheets at the cavity or location of the AM module (<FIG>).

Alternatively, the insert may include keying elements, notches, ribs or bosses which can engage with keying elements, notches, ribs or bosses arranged in at least the printed support sheet 14i.

At least two needles of the tray may pass through the inserts at the location of each AM module cavity in order to precisely position the printed support sheet 14i with respect to each insert.

Thus, the invention makes it possible to position the inserts precisely with respect to this plate with protrusions or needles.

The invention may provide at least one protrusion such as a needle, passing through the insert in an area within the antenna substrate cavity <NUM> and the AM module placement cavity while extending beyond the top surface of the insert in order to thread a hole in the printed support sheet 14i so as to position it precisely with respect to the table (or tray <NUM>) and consequently also with respect to the insert. The protrusion or needle may not extend heightwise as far as a cavity plane P1.

The invention can provide centring cores (not shown) to be placed in the cavities <NUM> and which comprise a needle (or peg or pin) oriented perpendicular to the plane of the metal insert, preferably in the region of the AM module cavity.

These cores may preferably comprise two needles, first and second, spaced as far apart as possible (or first and second positioning pins), configured to engage in the assembly tray and precisely position each insert since the core has substantially the shape of the cavity <NUM>. This core can also include a third needle (or pin) extending through a perforation of the printed support sheet in the area of the M module. These three needles can be distributed in the corners of the cavity of the radio-frequency module After pressing, the method provides for removing the centring and/or centre cores or keeping them in the lower tray <NUM> while the laminated structure is removed from the tray and turned over to be placed on a graphic printing table.

In step <NUM> (<FIG> and <FIG>), to facilitate assembly, a compensation sheet <NUM> to compensate for the thickness of the insert and for centring the insert, can be used by being threaded (or positioned) beforehand via its perforations <NUM>, <NUM> onto the needles <NUM>, <NUM> of the assembly tray <NUM>. For this purpose, the compensation sheet <NUM> may comprise corresponding perforations <NUM>, <NUM> similar to the perforations <NUM> of the support sheet <NUM>.

In the preferred and illustrated example, the method comprises the use of this thickness compensation sheet <NUM> for each insert. The compensation sheet comprises at least one housing <NUM> configured with the dimensions of the insert in order to receive the insert during the assembly and the perforations <NUM>, <NUM>.

Another advantage of the compensation sheet is to cover the edge or the peripheral strip of the insert <NUM> during a graphic printing of the free face of the insert (opposite to that adhering to the support sheet).

The insert <NUM> can then be inserted into the housing <NUM> of the compensation sheet and is thus positioned with respect to the positioning needles <NUM>, <NUM> via the compensation sheet. The compensation sheet may be configured with a flared or chamfered insert insertion rim at the mouth (periphery of the housing <NUM>) to facilitate the insertion of the insert.

Alternatively, without the compensation sheet <NUM>, the tray <NUM> may include a location or housing 29E formed in the tray and precisely indexed or marked with respect to the needles <NUM>, <NUM>. Here, the location 29E may correspond to the surface of a punch 29P sliding in the lower assembly tray <NUM>. The punch 29P can be set back as in <FIG> (or not) with respect to the upper level of the tray and thus defines a housing or location 29E corresponding to the dimensions of the main face of the metal insert <NUM>. The edge of the tray housing 29E may also have a chamfer or be flared to facilitate the insertion of the insert <NUM> onto the punch 29P inside the punch housing 29E. The second upper tray <NUM> may have a thickness similar to that of the first lower tray <NUM>.

The sheets or films of the assembly comprise, in the example, an adhesive film <NUM> to adhere at the same time to the metal of the insert <NUM> and to the plastic of the support sheet <NUM>, in particular here made of PVC. Other plastic sheets made of materials that are known to a person skilled in the art of the smart card industry can be used, such as ABS, natural or synthetic cellulose fibres, PET, polycarbonate, etc..

They also comprise in contact with the adhesive, the support sheet <NUM> which has a graphic printing layer 14i and a transparent protective layer (overlay) 14B of the graphic printing.

For the assembly, the method may optionally provide a film for lamination and protection of the tray and/or the card during lamination, between an upper lamination tray <NUM> and the sheets or films to be assembled.

During the lamination pressing (<FIG>) of the insert and the sheets listed above, the method may provide for actuating the punch 29P towards the upper tray <NUM> in order to increase the assembly pressure at the insert.

According to another feature of the preferred embodiment, the method can comprise a step of removing said support sheet <NUM> assembled with at least the insert <NUM> with respect to the first assembly tray <NUM>, as well as a step of turning over said structure to place it on a second tray <NUM> (not shown) having second positioning elements <NUM>, <NUM> (not shown), so that each insert <NUM> has a free outer face <NUM> exposed outwards. If necessary, the same tray <NUM> can be used and the elements <NUM>, <NUM> would then be identical to the positioning elements <NUM>, <NUM>.

In the example, in <FIG>, the product of the assembly <NUM> (<NUM>, <NUM>, <NUM>, <NUM> and optionally <NUM>) is removed from the lower <NUM> and upper <NUM> trays as well as from the needles <NUM>, <NUM>.

In step <NUM> (<FIG> and <FIG>), the resulting intermediate product 1B can then be turned over and transferred to a graphic printing station for graphic printing (step <NUM>) of the insert <NUM> on the free face <NUM> thereof.

According to one feature, the method comprises a step of inserting a radio-frequency module <NUM> into a cavity <NUM> formed in the insert and permeable to the radio-frequency field and a step of graphic personalisation of said outer face of the insert. The radio-frequency module <NUM> can typically comprise an antenna <NUM> on a substrate <NUM>.

In the example, the radio-frequency module <NUM> is inserted into the metal insert <NUM> after turning over the intermediate product obtained in <FIG>.

Alternatively, the module <NUM> can be inserted into the insert <NUM> before assembly with the sheets.

For this purpose, the insert <NUM> comprises or is formed of a metal plate P around said cavity <NUM>. The cavity <NUM> can be produced before assembly.

<FIG> illustrates an example of a cavity <NUM> and a radio-frequency module <NUM> inserted into the cavity. A relay antenna and/or a radio-frequency module <NUM> is produced on an insulating support substrate <NUM> in a format substantially corresponding to the cavity <NUM>.

In the case of a relay antenna 21R (not shown), its support substrate <NUM> can be assembled with the insert <NUM> so as to position the relay antenna 21R opposite the space (cavity) that is permeable to radio-frequency waves of the insert. The relay antenna 21R can replace the antenna with pads for interconnection 32i, 32j to a radio-frequency module. It is inductively coupled to a radio-frequency module antenna comprising a substrate, a module antenna connected to a radio-frequency integrated circuit.

The insert <NUM> may comprise a plate (<NUM>) with a slot (<NUM>) intersecting the plate in its thickness and extending from an outer periphery (<NUM>) of the plate to an inner periphery of the space or cavity <NUM> that is permeable to the radio-frequency field.

The radio-frequency module <NUM> may preferably be covered with a masking material (not shown). This masking material can be produced at the graphic printing station (step <NUM>) or at another station. The masking material can be deposited by graphic printing, screen printing, material jet, inkjet, lamination or film fixing.

Alternatively, the masking material of the antenna substrate can be applied after cutting or extracting the card. Subsequently, (still in step <NUM>) the method comprises a second graphic printing step <NUM> (<FIG>) directly on the surface <NUM> (<FIG>) of the metal insert <NUM>.

This printing <NUM> can advantageously be carried out after extracting the card or before extraction. Preferably, it is carried out while the insert is on the support sheet <NUM> with the thickness compensation sheet <NUM> so as to protect the strip or edge <NUM> of the card from the graphic printing.

In step <NUM>, the method extracts each metal smart card 1A from the printed support sheet <NUM> by cutting or machining the sheet around a peripheral contour of the insert.

The extraction can be carried out using a cutting tool of the die punch type, with blades or by shearing.

Alternatively, the method uses a cutting tool such as a milling cutter, a laser, blades, a water jet, etc., which approaches the edge <NUM> of the card until it touches it and which machines the support sheet directly above the contour <NUM> of the card.

Claim 1:
A method for manufacturing a metal smart card (1A, 1B) comprising a metal insert (<NUM>) having a peripheral edge (<NUM>) extending to the peripheral edge (<NUM>) of the card and at least one printed cover sheet (<NUM>), said method comprising the following steps:
- assembling a printed support sheet (<NUM>) and at least one insert (<NUM>) using an assembly tray (<NUM>) comprising elements (<NUM>, <NUM>) for positioning the support sheet and each insert (<NUM>),
- extracting each metal smart card (1A, 1B) from the printed support sheet (<NUM>) by cutting or machining the sheet around a periphery of the insert, characterised in that it comprises the use of a thickness compensation sheet (<NUM>) for each insert, said compensation sheet comprising at least one housing (<NUM>) configured to the dimensions of the insert in order to receive the insert during assembly, and perforations (<NUM>, <NUM>) configured to engage with said positioning elements (<NUM>, <NUM>) of the assembly tray in order to position them with respect to the insert.