Patent Description:
<CIT> discloses a dual interface smart card having a metal layer includes an IC module, with contacts and RF capability, mounted on a plug, formed of non RF impeding material, between the top and bottom surfaces of the metal layer. The plug provides support for the IC module and a degree of electrical insulation and isolation from the metal layer. The resultant card can have contact and contactless operating capability and an entirely smooth external metal surface except for the contacts of the IC module.

<CIT> illustrates for example a subscriber identity module (SIM) with a first and a second integrated circuit.

<CIT> and <CIT> disclose further examples of smart cards or methods for producing a smart card.

<CIT> relates to a chip card with a dual contact and contactless communication interface, including a microelectronic module and a card body provided with a cavity which can receive the microelectronic module, said microelectronic module being formed by a substrate, the first face thereof bearing a terminal block of electric contacts and a second face thereof bearing a first microelectronic chip electrically connected to the terminal block of electric contacts and a second chip electrically connected to the terminals of an antenna, the coils of which are disposed on the second face of the substrate of the electronic module. The card body includes a device for concentrating and/or amplifying electromagnetic waves, which can channel the electromagnetic flow received, in particular, from a contactless chip card reader toward the coils of the antenna of the microelectronic module.

The booster antenna or gap in the card body edge typically modifies the structural rigidity of the card and/or detracts from the overall "metallic" behavior of the card, such as the metallic sound produced when a metal card is dropped on a table. This metallic sound is a highly desirable feature of such cards to many who carry them. Accordingly, producing a metal transaction card with dual interface (contact and contactless) functionality, while maintaining the structural rigidity and desired "metallic" sound of the card, is highly desired.

Further advantageous embodiments are defined in the dependent claims. To solve the above technical problems, the present invention provides.

According to common practice, the various features of the drawings are not drawn to scale unless otherwise indicated.

The invention is best understood from the following detailed description when read in connection with the accompanying drawings, with like elements having the same reference numerals.

One aspect of the invention comprises a split, contact/contactless approach with a RF shielded payment sticker and a contact-only payment module. This enables contactless payment capability without requiring a booster antenna in the card body or incorporating a gap in the card body edge. Contactless payment stickers and RF shielded payment stickers are commercially available and have been deployed in the field (TBC Bank, <NUM>). RF Shielded payment stickers are also commercially offered by payment solution providers such as Gemalto (Gemalto Inc, <NUM>). See, e.g., Gemalto Optelio contactless Sticker, http://www. com/brochures-site/download-site/Documents/fs optelio contactless sticker. pdf; and TBC Bank Payment Sticker, http://www. ge/web/en/pay-sticker, both of which are examples of such stickers. An exemplary contactless sticker construction may be found in <CIT>.

To date however, these solutions have only been employed as "add ons" for cell phones so that no app or mobile wallet is required.

In one aspect of the invention, the contactless payment module may be embedded inside the metal card body as an adhesive inlay. Ferrite inside the inlay provides RF shielding from the metal card body. A contact-only module, as is known in the art, is applied to the front of the card to enable contact only transactions. In another aspect of the invention, the contactless payment module may comprise a disc or plug disposed in a through-hole in the card. In certain embodiments, the contact-only module comprises a first IC chip and the contactless-only module comprises a second IC chip, and each chip is independently personalized. Thus, while each chip may be encoded with information corresponding to the same user, the digital codes transmitted by each chip are typically different, are read by different types of readers, and ultimately are decoded using information that resides in different memory locations. The terms "disc" and "plug" are used interchangeably herein, and use of one should be understood to also encompass the other. To the extent the term "disc" may be understood to imply a round or cylindrical shape, the term "plug" should be understood to refer to an insert having any geometry capable of being retained in the through-hole that is formed. It should also be understood that the through-hole may also have any geometry, although its geometry is typically suitably matched to the geometry of the plug or disc (e.g. similar but slightly smaller in some embodiments to facilitate a press fit, or similar but having internal threads configured to mate with external threads of the plug or disc in other embodiments). In other embodiments, the plug or disc may have a geometry that is substantially similar to the through hole, with the disc or plug having one or more features, such as tabs, prongs, protuberances, slots, or other minor differences designed to create an interference or to mate with a mating feature in the hole, to retain the disc or plug in the hole.

<FIG> depicts an exploded view of a contactless transaction module in the form of a RF shielded transaction adhesive inlay <NUM> (inlay <NUM>, hereinafter) according to one embodiment of the invention. The terms sticker, inlay, adhesive inlay, disc, plug, contactless module and contactless transaction module may be used interchangeably herein.

The inlay <NUM> comprises an outer coated layer <NUM>, an antenna layer <NUM>, a ferrite layer <NUM>, a filler layer <NUM>, an adhesive layer <NUM> and a removable paper liner <NUM>. The individual layers may be arranged in the order shown in <FIG>, or, alternatively, the layers may be arranged in a different order. The total thickness of the inlay may be <NUM> inches (. <NUM>) to <NUM> inches (. <NUM>), for example.

In this embodiment, filler layer <NUM> may be composed of any polymer amenable to the construction of the inlay, such as PVC, PET, PETG, polycarbonate, PET, PLA, copolymers of the above or any other polymer known to the art. The filler layer <NUM> may dramatically change in thickness or composition depending on the structure of the contactless payment component.

The antenna layer <NUM> includes an integrated circuit that may contain software for open & closed loop payment systems, loyalty, identification and medical/social benefits. This IC is bonded to the antenna on the substrate. The antenna layer <NUM> is typically etched aluminum, but may use any antenna system known to the art, such as etched copper, copper wire, or "printed" antennas using conductive inks such as nanosilver. Printing methods may include nanojet/inkjet or screen printing. The pocket for the shielded RF adhesive inlay may be a blind pocket or a partial through hole, as shown in more detail in <FIG> & <FIG>.

The outer layer <NUM> may be formed from either paper or plastic and may be coated. A design may be printed on the outer layer <NUM>. The design may be applied by printing, lasering, perforating, embossing, etc. to impart the desired design. Printing methods may include nanojet/inkjet or screen printing.

Although referred to as a "paper/plastic layer" herein with reference to a common embodiment, it should be understood that the outer layer(s) of the contactless transaction module (in any and all embodiments described herein) are not limited to just paper and/or plastic, and may comprise any materials or combinations thereof known in the art capable of suitably transmitting the signals to and from the antenna <NUM>. Thus, the aesthetics of the contactless transaction module may also include an outer decorative layer comprising wood, leather, ceramic, crystal, shielded or perforated metal, foil, or the like to impart a desired look to the card.

The contactless transaction module <NUM> may be mounted in a pocket of the card. The pocket may be a blind pocket or a through hole, as will be described hereinafter with reference to <FIG>.

<FIG> and <FIG> depict an exemplary card <NUM> having a contact-only module <NUM> and a contactless module (in the form of inlay <NUM>). The contact-only module <NUM>, as is known in the art, may sit in a blind pocket <NUM> that is "flush" to the front surface <NUM> of the card <NUM> to enable contact only transactions. The inlay <NUM> may sit in a blind pocket <NUM> that is "flush" to the rear surface <NUM> of the card <NUM>, allowing for RF transmission and thus payment transactions from only one side of the card (the side to which the pocket <NUM> opens). The metal above the blind pocket <NUM> prevents RF transmission towards the front of the card, but RF transmission out through the top of the inlay <NUM> is possible as the ferrite <NUM> provides shielding from the metal layer. The antenna of the adhesive inlay <NUM> is tuned to optimal performance to accommodate the effects of the metal and ferrite. Although most convenient for assembly in a sticker format comprising all of the layers shown in <FIG> assembled in a inlay from which the liner <NUM> is removed from the adhesive <NUM> and the inlay <NUM> pressed into place in the pocket <NUM>, it should be understood that the contactless module <NUM> for placement in the pocket <NUM> may have any number of constructions, including a construction in which it has no adhesive and adhesive is applied to the hole before inserting the module. In still other constructions, the antenna module inlay may be retained in the pocket other than adhesively. Furthermore, it should be understood that multiple inlays <NUM>, each having an adhesive layer <NUM>, may be stacked on top of one another in the pocket <NUM>, with each inlay <NUM> containing one or more layers required to complete the assembly. Similarly, the layers may be disposed in situ in the pocket by any method known in the art to securely bind them in place, not limited to adhesive bonding.

<FIG> and <FIG> depict an exemplary card <NUM> having a contact-only module <NUM> and a contactless module <NUM>. <FIG> and <FIG> show a construction using a "through hole" design. In this design, the contactless module <NUM> in the form of a payment "plug" or disc <NUM> is press-fit or threaded within a through-hole <NUM> in the card <NUM> extending from the front to the back of the card <NUM>. The disc <NUM> is held in place (i.e., fixed) in the hole <NUM>.

In some embodiments, the plug or disc <NUM> may be relatively rigid and permanently held in place within the card body. Due to the complete removal of metal from the hole <NUM>, RF transmission from both sides of the card <NUM> is possible and ferrite is typically not required in the plug or disc <NUM>, giving the card <NUM> a higher performance level.

As shown in <FIG>, the plug or disc <NUM>, like the inlay <NUM> of <FIG>, may comprise a multi-layer design that includes the antenna and embedded IC layer, one or more filler layers above and/or below the antenna layer, and one or more outer coated paper/plastic layers, each of which is disposed to rest flush with the respective card surface and may have a design. Alternative variants 24a and 24b of the disc <NUM> are described hereinafter with reference to <FIG>, respectively.

In other embodiments of the disc 24a and 24b, illustrated in <FIG>, respectively, at least the antenna and embedded IC layer comprising the contactless module may be part of inlay <NUM> or <NUM> (having at least adhesive and liner layers on one side) that is adhesively bonded to a separate plug or disc <NUM>, <NUM> or <NUM>, which may have an outer coated paper/plastic layer disposed to align with the external surface of the card and optionally, a filler layer. Such an inlay may have an outer surface designed to lay flush with the outer surface of the card, such as inlay <NUM> shown in <FIG>, or, as shown in <FIG>, plugs <NUM> and <NUM> may be disposed on both sides of inlay <NUM>. The adhesive layers may be disposed on the inlay, on the plug, or on both. The multi-layer design of each disc <NUM>/24a/24b may comprise layers that are bonded to another by any means known in the art, including adhesively.

Thus, methods for manufacturing the card may comprise any process for forming a card with a contact chip known in the art, in which the additional steps required to add contactless capability may be interposed at any point in the processing. The steps for adding contactless capability comprise first creating a void in the card body, such as by milling, etching, drilling, etc.. The void may be in the form of a pocket <NUM>, as shown in <FIG>, or a through hole <NUM> as shown in <FIG>. Then, the contactless module is placed in the void. In the process shown in <FIG>, placement of the contactless module <NUM> comprises adhesively bonding a contactless transaction inlay <NUM> in the pocket <NUM>. In one embodiment, the contactless transaction module comprises a multi-layer adhesive inlay <NUM> as shown in <FIG>.

In the process shown in <FIG>, placement of the contactless module <NUM> comprises placing a contactless transaction plug or disc <NUM> in the through-hole <NUM>. This process may comprise press fitting, threading, or disposing by any other means known in the art, a module as shown in <FIG> and <FIG> into the through-hole. The contactless module may be a multi-layer module comprising at least the antenna / IC module and the outer-coated paper/plastic layers, and, typically one or more filler layers of <FIG>. Such embodiments may have no ferrite layer and typically have no adhesive or liner layers.

As shown in <FIG>, in one embodiment, the metal card may comprise two pieces <NUM>, <NUM> and the module <NUM> may have at least two opposing radial tabs <NUM> and <NUM> adjacent to the through-hole, which tabs are disposed in with slots in the card body pieces such that the tabs hold the insert in place. Although shown with slots in both body pieces <NUM> and <NUM>, it should be understood that the slots may be present in only one of the two pieces. In other embodiments, the tabs may be thin enough that no corresponding slots are needed. Although depicted as two discrete tabs, it should be understood that any number of tabs may be provided, including only a single tab in the form of a continuous radial protrusion that surrounds the entire periphery of the disc/plug may be provided. In the embodiment depicted in <FIG>, the contact-only module <NUM> may be inserted in a through hole in metal body piece <NUM>, and may have a similar tab or set of tabs and optional corresponding slots to hold it in place. In other embodiments, the disc/plug, or one or more portions thereof, may be press-fit or adhesively bonded in the through-hole in the card as is shown in <FIG>. Module <NUM> may be inserted in a single step or the multiple layers of the module may be assembled in place in the corresponding through-hole, as is explained further herein.

In other disc/plug embodiments, it may be desirable to include a ferrite component. In particular, the disc/plug may include a ferrite component comprising a "ring" of ferrite in one or more of the layers to shield from the metal edges but still allow RF transmission in both directions perpendicular to the plane of the card. The ferrite ring may be disposed about the entire thickness of the disc/plug, just in one layer, or in multiple layers. For example, as shown in <FIG>, a disc/plug comprising outer design layers <NUM>, filler layers <NUM>, and antenna layer <NUM> as described herein, may have a ferrite "ring" <NUM> enveloping the entire periphery (but not the upper and lower surfaces of the disc/plug). Although referred to as a "ring," it should be understood that the ferrite may have any annular geometry, including circular, square, etc., and may or may not necessarily have the same shape as the disc/plug as a whole. The ferrite may be, without limitation, in the form of a coating or a sleeve into which the other layers are stacked. In another embodiment, as shown in <FIG>, a disc/plug <NUM> may comprise outer layers <NUM>, filler layers <NUM>, and antenna layer <NUM>, in which the ferrite <NUM> is disposed only in one layer. Although shown disposed in the antenna layer <NUM>, it should be understood that the ferrite <NUM> may be isolated in its own layer or layers, and may be present in any one, all, or multiple but fewer than all of the layers in the stack (and, additionally, the stack is not limited to only the layers or all of the layers shown). Thus, the ferrite component <NUM> may extend in the relevant dimension from the front surface of the card to the back surface of the card, or may extend dimensionally less than surface to surface.

Furthermore, although depicted in both <FIG>, it should be understood that the ferrite component may not necessarily be the outermost material, and that other components (e.g. filler) may comprise the outer periphery and/or lie between the ferrite and the disc/plug outer periphery that lies in contact with or otherwise closest to the card body. However, the annular ferrite component is generally disposed at the outer periphery of the plug or disc or near the outer periphery (i.e. relatively closer to the outer periphery than to a central axis of the disc or plug) to provide appropriate shielding for the components disposed in the annulus formed by the ferrite component. Although the ferrite ring <NUM>/<NUM> is illustrated herein with respect to a disc/plug embodiment configured for placement in a through-hole in the card body, it should be understood that this feature may also be applied to embodiments intended for placement in a blind pocket in the card body.

In other embodiments, the process of placing the contactless transaction plug or disc in the pocket may comprise disposing at least a first plug or disc in the through-hole, and placing a contactless transaction module on top of the plug or disc, such as in the form of an adhesive inlay, as shown in <FIG>. In such an embodiment, the contactless transaction inlay comprises at least the antenna / IC module, a first outer-coated paper/plastic layer for resting flush with one surface of the card, and the adhesive and liner layers (with the liner layer being removed before adhering the sticker to the plug, and the plug may comprise the filler layer and a second outer-coated paper plastic layer for resting flush with the other surface of the card. In yet another embodiment, the process of placing the contactless transaction plug or disc in the pocket may comprise disposing the first plug or disc in the through-hole, placing a contactless transaction module on top of the first plug or disc, and placing a second plug or disc atop the contactless transaction module, as shown in <FIG>. In such an embodiment, the contactless transaction sticker comprises at least the antenna / IC module and one or more adhesive layers (with removable liner paper disposed over the adhesive layer until the step of adhering the sticker to the plug), and each plug comprises at least an outer-coated paper/plastic layer for resting flush with an outer surface of the card, and typically also a filler layer, and may also include one or more adhesive layers. In this embodiment, the adhesive layers may be provided as part of the plug or the contactless module, or both.

It should be understood that in a multilayer disc or plug as described above with respect to <FIG>, assembly of the multilayer disc or plug may comprise providing one or more of the layers as described herein in the form of a adhesive inlay, and adhering that adhesive inlay to one or more of the other layers to assemble the multi-layer component. The assembly process may comprise, for example, the assembly of a sheet containing multiple antenna/IC modules and paper/plastic outer layers comprising multiple, discrete printed units aligned with each antenna/IC module, and stamping or cutting out each multilayer disc or plug from the assembled multi-layer sheet to create the discs or plugs are then disposed in the through-hole.

Thus, in one multi-layer embodiment of the plug or disc <NUM> shown in <FIG>, the antenna/IC module <NUM> may be sandwiched between discrete filler layers 59a and 59b, such as may be assembled by the method described above (with adhesive layers not shown in <FIG>). The module <NUM> and the filler layers 59a and 59b are sandwiched between two outer layers <NUM> and <NUM>.

In another embodiment of the plug or disc <NUM> shown in <FIG>, antenna/IC module <NUM> layer may be embedded in a filler layer <NUM> that surrounds the antenna/IC module <NUM> layer on all sides. The filler layer <NUM> is sandwiched between outer layers <NUM> and <NUM>. Filler layer <NUM> may actually comprise two layers (not shown), each with a pocket formed to accommodate the antenna <NUM>, or one layer with a pocket and one layer covering the pocket opening, or the two filler layers may have no pockets and may be laminated together to create a sealed portion around the edges of the antenna/IC module <NUM>.

The following example shown in <FIG> is not according to the invention and is present for illustration purposes only. The scope of the protection of the invention is solely determined by the appended set of claims. In yet another embodiment, depicted in <FIG>, card body <NUM> may have a configuration for accommodating a dual interface module. Body <NUM> may have a through hole <NUM> formed within a pocket <NUM>. Pocket <NUM> may be milled out to accommodate an inlay, such as adhesive inlay <NUM> of <FIG>.

Adhesive inlay <NUM> comprises a first portion <NUM> having the ferrite and antenna structure as described herein, and a second portion <NUM> configured to inductively couple to the module and having no ferrite. The ferrite may be removed or omitted during fabrication of the inlay <NUM>, or the ferrite may be milled away during the process of embedding the module.

As shown in the profile view of <FIG>, the inlay <NUM> may further have a plug <NUM> bonded to the module coupling area for the contact module to be embedded into. Plug <NUM> may be any non-metallic material, such as plastic. An advantage of the configuration shown in <FIG> and <FIG>, is that it permits use of a single dual interface module rather than two separate IC (one for contact and one for contactless). In the other embodiments described herein, the contact-only and the contactless-only chips are not physically connected to one another or in communication with one another, meaning that they typically need to be separately personalized. Having a single module increases personalization speed when the card is assigned to a user. Although described with the contact module (including the integrated circuit (IC) shared by both the contact and contactless interfaces) embedded in the plug, it should be understood that the common IC may be embedded in the plug or in the sticker. What is important is that the contacts exposed on the surface of the card (and embedded in the plug) that physically connect to a card reader are connected to the same IC as the antenna structure (embedded in the sticker) used for a contactless interface with a card reader.

In one, exemplary implementation, inlay <NUM> is fabricated with plug <NUM> bonded to the contactless module inlay <NUM>. Separately, card body <NUM> is formed, hole <NUM> is laser cut, and pocket <NUM> is milled. The inlay / plug combination is then inserted in the pocket/hole in the card body, and a module is embedded in or otherwise bonded to the plug, or the module may be embedded into the plug before insertion into the pocket/hole in the card body. The embedding process may comprise removing ferrite from the sticker underlying the plug, or the sticker may be fabricated with the ferrite removed prior to insertion of the sticker into the pocket, or prior to attachment of the plug to the sticker.

In still another embodiment, depicted in <FIG>, plug <NUM> (and the associated contact module embedded therein) may be installed separately in the card body from the contactless module inlay <NUM>. The contactless module inlay may have an etched, printed or wire RF antenna. In one method, pocket <NUM> may be formed first in body <NUM>, then the contactless module inlay <NUM> is inserted in the pocket, and then hole <NUM> is milled down to the contacts (not shown) of the contactless module inlay, and the plug (and contact module) is connected to those contacts, such as via wire bonding or flip chip bonding. In still another embodiment, the hole <NUM> and pocket <NUM> are cut and the plug <NUM> (and contact module embedded therein) are inserted in the hole, with a connection (e.g. contact pads, not shown) to the contact module exposed, and then the contactless module inlay <NUM> is applied to the pocket with contacts (not shown) of the contactless module inlay mating to the connection to the contact module. In all of the foregoing, it should also be understood that the term "plug" refers to any isolation disposed around the contacts and any IC connected thereto in hole <NUM>. Although plug <NUM> is shown and described as a freestanding member in <FIG>, it is not limited to any particular construction, especially in embodiments in which the contact and surrounding isolation are disposed in the card separately from the contactless module inlay.

In another exemplary construction, referring to <FIG>, rather than connecting directly via contacts to the payment module, the contactless module inlay <NUM> antenna may inductively couple with a standard inductive coupling dual interface (DI) module embedded in plug <NUM>, such as a standard DI module known in the art.

In yet another embodiment, the payment IC is mounted to the contactless inlay, such as by wire bonding or flip chip bonding. The inlay may have an etched, printed, or wire RF antenna. The inlay provides functionality for the card to conduct contactless transactions. <FIG> depicts a card body <NUM> having a payment IC <NUM> mounted on contactless inlay <NUM>. <FIG> depicts the standard layout <NUM> of the contact pins of a contact module in an exemplary card <NUM>. Traces <NUM> for pins <NUM> -<NUM> are run from the payment IC to the contact module area, and, for example, laminated into the body of the card or the inlay. A hole is milled to accommodate the contact pins <NUM> on the front face of the card. A "false" module faceplate <NUM> with no IC connected is bonded to the traces <NUM> on the inlay so the IC <NUM> on the inlay can conduct both contact and non-contact transactions. Each trace is bonded to the appropriate pin <NUM>-<NUM> on the IC <NUM>. In order for the faceplate <NUM> to reach the traces of the inlay physically and make an electrical connection, copper (or any electrically conductive) pads may be installed on the inlay <NUM> or the faceplate <NUM>. The electrical connection between the faceplate and the inlay may be accomplished by, for example, ACF tape, soldering, or conductive epoxy. Providing a direct connection between the payment module <NUM> and the contactless antenna may help avoid problems arising from poor connectivity between the contactless antenna and the payment module when they are only inductively coupled to one another.

The card as described herein is thus a "full metal" card in the sense that it comprises a continuous metal edge and the metal card body has a unitary construction that is not disrupted with a booster antenna embedded in the metal body itself. The non-metal components in the pocket or through-hole do not have the same detrimental effect on the metallic sound of the card as do the antenna or edge gap.

In still another embodiment, rather than being inserted in a pocket or through-hole, the contactless module may be constructed as a full-face layer that is adhesively bonded to one side of the metal card. The contactless module so constructed may interface with the other component cards in any of the ways described herein (i.e. it may be separately personalized relative to the contact-only module, a single operative dual interface IC may reside on the full-face layer and connect via a contact pad to the contact-only faceplate, or a single operative dual interface IC may reside on the card and may connect to an antenna-only full face layer via contacts or via inductive coupling. The full-face contactless module layer may have one or more further layers bonded thereto, such as a layer comprising, for example, the magnetic strip, signature pad, bar code, cardholder photo, holograms, branding, printed security codes, and the like.

Claim 1:
A dual interface transaction card (<NUM>, <NUM>), comprising:
a metal card body (<NUM>, <NUM>) having first and second surfaces;
a first transaction module (<NUM>, <NUM>) for enabling contact-only transactions secured in the card body (<NUM>, <NUM>), the contact-only transaction module (<NUM>, <NUM>) comprising contact pads disposed on the first surface of the card body (<NUM>, <NUM>) and comprising a first integrated circuit chip;
a second transaction module (<NUM>, <NUM>) for enabling contactless transactions secured in a void in the metal card body (<NUM>, <NUM>), the contactless transaction module (<NUM>, <NUM>) comprising a second integrated circuit chip and an antenna,
wherein the first integrated circuit chip and the second integrated circuit chip are not physically electrically connected to one another or in communication with one another,
characterised in that the void comprises a blind pocket (<NUM>, <NUM>) open to the second surface of the card body (<NUM>, <NUM>).