Patent ID: 12204966

DETAILED DESCRIPTION

The present disclosure generally relates to a dual interface metal card having a current notch formed therein to reduce eddy currents generated in a metal card core. The dual interface metal card has a circuit core positioned between a first metal portion and a second metal portion. The first and second metal portions each define a cutout, such as an antenna cutout. The first and second metal portions further define a discontinuity extending from the cutout to a first edge of the metal card core.

FIG.1illustrates a card core2of a dual interface card, in accordance with some embodiments. The card core2includes a body4. In the illustrated embodiment, the body4includes a generally rectangular shape defined by a plurality of short edges12a,12band a plurality of long edges14a,14b, although it will be appreciated that the metal core2can include any suitable shape, such as any suitable regular or irregular geometric shape (e.g., square, rectangle, circle, trapezoid, rhombus, triangle, etc.). The body4may include any suitable material, such as a metal material, a partially metal material, a conductive non-metal material, a non-conductive non-metal material, and/or any other suitable material. The body material may be selected to provide one or more predetermined features, such as a feel, strength, resiliency, harmonic, and/or other feature, to a card formed using the card core2. Example materials include, but are not limited to, stainless steel, tungsten, spring steel, etc. In some embodiments, the body4may include a combination of conductive and/or non-conductive materials. Example non-conductive materials include, but are not limited to, wood, ceramics, non-conductive plastics, etc.

In some embodiments, the body4defines a void or cutout8. The cutout8may include multiple portions each having separate geometries. For example, in the illustrated embodiment, the cutout8includes a first portion8adefined by a circular opening in the body4and a second portion8bdefined by a square opening in the body4, although it will be appreciated that each of the cutout portions8a,8bmay have any suitable geometry. As shown inFIG.1, in some embodiments, two or more cutout portions8a,8bmay overlap such that the first cutout portion8ais continuous with the second portion8b. In some embodiments, the cutout8is positioned adjacent to a first short edge12aof the card core2.

In some embodiments, the body4may define a plurality of cutouts8each having one or more portions. The plurality of cutouts8may be spaced about the body4such that each of the cutouts is separated by a portion of the body4. For example, in some embodiments, the body4may define a first cutout8as illustrated inFIG.1and a second cutout (not shown) located adjacent to a second short edge12bof the body4. Although the card core embodiments discussed herein include a single cutout8defining multiple portions, it will be appreciated that the various structures, systems, and methods disclosed herein apply equally to card cores having multiple cutouts and are within the scope of this disclosure and the appended claims.

Each portion8a,8bof the cutout8may be sized and configured to receive a circuit element therein. Each portion8a,8bof the cutout8defines an opening such that the a circuit element positioned within the cutout8can be effectively electromagnetically isolated from the surrounding material of the body4. The effective spacing (or gap26, seeFIG.2) between a circuit element and the edge9of the cutout8may vary based on the circuit element positioned within the cutout8(or a portion8a,8bthereof). For example, in some embodiments, each circuit element positioned within the cutout8may be spaced at least 300 microns, at least 500 microns, at least 700 microns, and/or any other suitable spacing from the edge9of the cutout8to effectively isolate a circuit element positioned within the cutout8from the material of the body4. It will be appreciated that the spacing may be larger and/or smaller based on the circuit element positioned within the cutout8and/or properties of the card core2(for example, based on the material of the card core2).

In some embodiments, the body4defines a sinuous line discontinuity10extending from an outer edge (such as first short edge12a) of the body4to an inner edge10of the cutout8. The sinuous line discontinuity10includes a break or channel in the body4such that a continuous circular path does not exist within the body4that extends around the cutout8. The sinuous line discontinuity10can include any suitable gap within the body4sufficient to effectively prevent electromagnetic coupling between a first edge20aand a second edge20bof the body4defining the sinuous line discontinuity10. For example, in some embodiments, the sinuous line discontinuity10includes a channel having a width of about 300-900 microns, at least 300 microns, at least 500 microns, at least 700 microns, up to 1000 microns, up to 2000 microns, etc., although it will be appreciated that discontinuities of greater and/or lesser size can be used and are within the scope of this disclosure.

In some embodiments, the sinuous line discontinuity10defines a plurality of flexible fingers22a,22b, for example, a first flexible finger22aand a second flexible finger22b. the flexible fingers22a,22bmay be arranged in a parallel relationship and are configured to provide a flex profile similar to the continuous portion of the body4when a force is applied to a card including the card core2. For example, and as discussed in greater detail below, the card core2may be incorporated into a credential card, such as a credit card, biometric card, etc. The credential card may include a plurality of additional layers and/or materials, such as, for example, thermoplastic layers, adhesive layers, polymer layers, etc. The length and width of each of the flexible fingers22a,22bmay be selected such that the portion of the credential card containing the sinuous line discontinuity10provides a flex profile similar to the solid portions of a finished credential card. The flexible fingers22a,22bare configured to prevent cracking, breaking, and/or deformation of the card core and/or additional material layers formed on and/or around the sinuous line discontinuity10.

The sinuous line discontinuity10and the flexible fingers22a,22bare configured to distribute pressure applied to a finished credential card incorporating the card core2to allow bending in the finished credential card. The sinuous line discontinuity10and the flexible fingers22a,22bare selected so as to provide a flex profile similar to the remainder of the finished credential card (i.e., the portion of the credential card incorporating the solid sections of the body4) to prevent cracking of any layer of the finished credential card when bending pressure is applied. The sinuous line discontinuity10prevents card stress and breakage by distributing the surface area and torque pressure of an applied force evenly across the finished credential card (and the card core2), avoiding cracking and/or breakage in a finished credential card or similar card containing the card core2.

In some embodiments, the flexible fingers22a,22bare sized and configured such that each flexible finger22a,22bis configured to flex out-of-plane at a maximum predetermined angle with respect to the an adjacent portion of the body4. For example, in some embodiments, the each flexible finger22a,22bis configured to provide a flex profile that allows an out-of-plane flex of up to 120° with respect to an adjacent planar portion of the body4. The flex profile of each of the flexible fingers22a,22bis selected to prevent cracking, marking, and/or permanent bending of a finished credential card that incorporates the card core2therein. In some embodiments, the flex profile is selected such that each flexible finger22a,22bprovides a similar response in the area of the sinuous line discontinuity10as would be provided by a solid portion of the body4positioned in the same location, although it will be appreciated that each flexible finger22a,22bcan provide a greater or lesser flex if necessary to provide a proper flex response of a finished credential card.

In some embodiments, the sinuous line discontinuity is configured to reduce and/or eliminate eddy currents generated in the body4during operation. For example, in some embodiments, exposure of a card core2comprising a metallic, semi-metallic, or other conductive material to one or more electromagnetic signals typically generates one or more eddy currents in the conductive body4. Eddy currents flow in a closed loop within the conductor (e.g., body4). The sinuous line discontinuity eliminates any conductive loop around the cutout8and effectively reduces the area available for eddy currents. The sinuous line discontinuity effectively reduces and/or eliminates eddy currents (and other signals) generated in and/or by the body4. Although a single sinuous line discontinuity is illustrated, it will be appreciated that a card core2can include a plurality of cutouts8each having one or more discontinuities10extending from an outer edge12a,12b,14a,14bof the body4.

In some embodiments, the sinuous line discontinuity10includes a plurality of curved portions34a-34dcoupled by a plurality of substantially straight portions36a-36c. The plurality of substantially straight portions36a-36ceach extend substantially parallel to each other over a predetermine length of the card core2. In some embodiments, the sinuous line discontinuity10defines a smooth, repetitive oscillating curve (e.g., a sinusoidal curve), although it will be appreciated that the discontinuity10can include sharp (e.g., non-smooth) curved portions and/or non-parallel portions and such sinuous line discontinuity10is within the scope of this disclosure. In various embodiments, the card core2can include a plurality of cutouts8each having at least one sinuous line discontinuity10extending from an inner edge of the cutout9to an outer edge12a,12b14a,14bof the body4.

For example, in the illustrated embodiment, the sinuous line discontinuity10includes a first portion38extending from the cutout8, a plurality of substantially straight portions34a-34cextending at a non-parallel angle with respect to the first portion38, a plurality of curved portions32a-32dcoupling the substantially straight portions34a-34 cm each having a predetermined curvature over a predetermined area, and an second portion40extending at a predetermined angle with respect to the substantially straight portions36a-36cto a first edge12aof the card core2. It will be appreciated that the curved portions32a-32dcan include any suitable curvature, such as, for example, any curvature between 45°-315°, 135°-225°, 160°-200°, 90°-270° and/or any other suitable curvature. It will be appreciated that the a card core2can include additional and/or different discontinuities, for example, as illustrated inFIGS.5-6.

The cutout8and/or the sinuous line discontinuity10may be formed using any suitable method. For example, in various embodiments, the cutout8and/or the sinuous line discontinuity10may be formed using one or more of a milling technique, an etching technique, a molding technique, and/or any other suitable technique. It will be appreciated that the cutout8and the sinuous line discontinuity10may be formed using the same and/or different techniques. In some embodiments, the sinuous line discontinuity10is formed in the card core2prior to the card core2receiving any circuit elements within the cutouts8.

FIGS.2and3illustrate the card core2ofFIG.1having a plurality of circuit elements positioned within the cutout8, in accordance with some embodiments. As shown inFIG.2, in some embodiments, a first circuit element16a, such as an antenna18, may be positioned within a first portion8aof a cutout8. The antenna18includes a plurality of concentric wire coils. The antenna18can include any suitable antenna, such as a printed antenna including one or more circular coils. Although a generally circular antenna is illustrated, it will be appreciated by those skilled in the art that the antenna18can have any suitable shape and/or any suitable number of windings (or coils). In some embodiments, the first circuit element16acan include a minimum thickness, such as, for example, a thickness between 50 and 100 microns, between 75 and 90 microns, and/or any other suitable thickness. The thickness of the first circuit element16amay be less than, greater than, and/or equal to the thickness of the card core2.

The first circuit element16ais positioned within the first cutout portion8asuch that a gap26is maintained between the edge9of the cutout8and the outer edge of the first circuit element16a. For example, in the illustrated embodiment, the antenna8is positioned to ensure a gap26suitable gap, such as at least 300 microns, at least 500 microns, at least 700 microns, 300-900 microns, up to 1000 microns, up to 2000 microns, and/or any other suitable gap is maintained between an outer coil of the antenna18and the edge9. Although specific embodiments are discussed herein with respect to the illustrated circuit elements, it will be appreciated that the gap26can include any gap sufficient to electromagnetically isolate the first circuit element16afrom the material of the body4.

In some embodiments, the gap26is selected based on one or more dimensions of the card core2and/or a credential card formed from the card core2. For example, in some embodiments, the gap26is a distance equal to at least the width of a finished credential card formed using the card core2. A finished credential card may have any thickness sufficient to contain the card core2, one or more circuit elements positioned within the cutout8, and/or any additional layers formed around the card core2. For example, a finished credential card may have a thickness of at least 700 microns, at least 750 microns, at least 800 microns, etc.

In some embodiments, the first circuit element16ais coupled to a plurality of contact pads24a,24bpositioned within the second cutout portion8bof the cutout by a plurality of leads28a,28b. The contact pads24a,24bare sized and configured to couple a second circuit element16b(seeFIG.3), positioned within the second cutout portion8b, to the first circuit element16a. The contact pads24a,24bare positioned within the second cutout portion8bto allow the second circuit element16bto be coupled to the contact pads24a,24bwhile maintaining at least a second predetermined gap30(seeFIG.3) between the edge9of the cutout8and the second circuit element16b. In some embodiments, the contact pads24a,24bare omitted and the second circuit element16bmay be directly coupled or not coupled to the first circuit element16a.

In some embodiments, the first circuit element16a, the contact pads24a,24b, and the leads28a,28bare formed integrally on a supporting film17(seeFIG.5). The supporting film17is sized and configured to be received within the cutout8while maintain the predetermined gaps26,30between the circuit elements16a,16band the edge9of the cutout8. The first circuit element16a, the contact pads24a,24b, and/or the leads28a,28bmay be formed integrally on the supporting film17using any suitable formation method. For example, in some embodiments, the first circuit element16a, the contact pads24a,24band/or the leads28a,28bare printed circuit elements that are printed onto the supporting film17using a process to print conductive traces and/or other materials. Although embodiments are discussed herein including printed circuit elements, it will be appreciated that the first circuit element16a, the contact pads24a,24band/or the leads28a,28bmay be formed using any suitable method.

FIG.3illustrates the card core2ofFIG.2having a second circuit element16bpositioned within a second portion8bof the cutout8. The second circuit element16bcan include any suitable circuit element, such as, for example, an active circuit element(e.g., a direct contact System-on-Chip (SoC) element)32. The second circuit element16bmay be positioned over and coupled to the contact pads24a,24bpositioned within the second cutout8b. The second circuit element16bis electromagnetically isolated from the body4of the card core2. For example, in the illustrated embodiment, the direct contact SoC element32is limited to direct contact coupling between the SoC element32and the antenna18and does not include any inductive coupling elements, effectively isolating the SoC element32from the material of the body4. In some embodiments, the second circuit element16bmay be positioned a predetermined distance from the edge9of the cutout8such that a second circuit element16bcapable of inductive, conductive, or other contactless coupling is effectively isolated from the material of the body4.

In some embodiments, the contact pads24a,24band the first circuit element16aare maintained in a co-planar relationship (i.e., are parallel with respect to a plane defined by the body4). When the contact pads24a,24band the first circuit element16aare co-planar, a second circuit element16bcoupled to the contact pads24a,24bwill be positioned out-of-plane (i.e., above or below) the first circuit element16a. In such embodiments, the second circuit element16bis coupled to the first circuit element16aonly through the leads28a,28band does not include any additional coupling (i.e., inductive, conductive, etc.) between the second circuit element16band the first circuit element16a.

In some embodiments, the second circuit element16bincludes a second antenna (not shown). The second antenna can have a different configuration as compared to the antenna16(e.g., greater and/or lesser antenna area, larger/smaller material, different shape, etc.) such that the second antenna produce different responses as compared to the antenna16when each is simultaneously exposed to the same electromagnetic signal.

In some embodiments, the card core2and the plurality of circuit elements16a,16bpositioned within the cutout8can be coupled between one or more additional layers, materials, and/or surfaces to form a credential core and/or a finished credential card (e.g., a credit/debit card, and ATM or bank card, an identification card, a state issued license or identification (e.g., driver's license), a security badge, a loyalty card, biometric card, etc.). The additional layers can include any suitable materials, such as, for example, metal, plastic, vinyl, and/or other materials.

FIG.4is a flowchart illustrating a method100of forming a credential card including a card core2, in accordance with some embodiments. At step102, a card core2including a body4defining at least one cutout8is formed. The card core2can be formed using any suitable technique, such as, for example, pressing, stamping, milling, molding, etc. In some embodiment, the body4is formed defining the cutout8. In other embodiments, a solid body is formed and the cutout8is subsequently formed in the solid body using any suitable technique, such as, for example, milling, drilling, etching, cutting, etc.

At step104, a sinuous line discontinuity10is formed in the body4extending from a first edge12aof the body4to the cutout8. The sinuous line discontinuity10can be formed using any suitable technique, such as, for example, etching, stamping, laser cutting, mechanical cutting (milling or other mechanical/contact cutting), water-jet cutting, etc. The sinuous line discontinuity10includes one or more curves34a,34band one or more straight line segments36a-36c. In some embodiments, the straight line segments36a-36care parallel and define a plurality of fingers22a,22bconfigured to provide a flex profile substantially similar to the flex profile of the body4.

At optional step106, a surface5of the body4may be treated to form one or more patterns and/or images on the surface. For example, in some embodiments, the surface of the body4may be etched, milled, and/or otherwise processed to form a predetermined pattern, images, pictures, symbols, trademarks, words, pictograms, or other visual indicators. In some embodiments, at least a portion of the surface5may be colorized using any suitable colorization process, such as, for example, inking, printing, sintering, etc. The colorization may be in combination with and/or alternative to the formation of one or more patterns or images through surface treatment. Although steps102-106are illustrated as separate steps, it will be appreciated that steps102-106may be integrated into and/or performed simultaneously one or more of steps102-106, and each combination is within the scope of this disclosure.

At step108, one or more circuit elements are positioned within the cutout8defined in the card core2. For example, in some embodiments, a first circuit element16a, a plurality of contact pads24a,24b, and a plurality of leads28a,28bare formed on a circuit core using any suitable method. For example, the first circuit element16a, a plurality of contact pads24a,24b, and a plurality of leads28a,28bmay include printed circuit elements formed on the circuit core. The circuit core is positioned within the cutout8such that a first gap26is defined between the first circuit element16aand the edge9of the cutout8to effectively electromagnetically isolate the first circuit element16afrom the material of the body4. The circuit core and/or the individual circuit elements may be positioned using any suitable method, such as, for example, by hand, by a pick-and-place method, and/or using any other suitable method. In some embodiments, a second circuit element16bmay be positioned within the cutout8, for example, within a second portion8bof the cutout8simultaneous with the placement of the first circuit element16aand/or the contact pads24a,24b.

At step110, a credential core200including the card core2is formed. The credential core may be formed by coupling a thermoplastic layer80on a first side of the card core2, as illustrated inFIG.5. The thermoplastic layer80may be simultaneously coupled to the card core2and/or the circuit elements16apositioned therein so as to form a credential core200. In some embodiments, the thermoplastic layer80is coupled to the card core2at a predetermined pressure and/or at a predetermined temperature. The thermoplastic layer80may include any suitable material, such as, for example, a moly-based material (e.g., molybendum), polyvinyl chloride (PVC), a copolymer of vinyl chloride, polyolefin, polycarbonate, polyester, polyamide, acrylonitrile butadiene styrene copolymer (ABS), and the like. Examples of PVC films suitable for use with the invention are available from suppliers such as Klockner Pentaplast of America, Inc. of Gordonsville, VA; and Shijiazhuang Eurochem Co. Ltd of China. Examples of such a vinyl chloride copolymer resin are available from Dow Chemical Company under trade name of UCAR®, and from BASF of Ludwigshafen, Germany under trade name of Laroflex®. In some embodiments, a material layer82may be positioned between the thermoplastic layer80and the card core2. The material layer82may include any suitable material, such as, for example, a cross-linkable polymer, an adhesive, and/or any other suitable material. Examples of cross-linkable polymers are disclosed in U.S. Pat. No. 9,275,321, granted on Mar. 1, 2016, and entitled “Information Carrying Card Comprising a Cross-Linked Polymer Composition, and Method of Making the Same,” the disclosure of which is incorporated herein by reference in its entirety.

At optional step112, a credential card may be formed by positioning one or more additional layers above and/or below the credential core formed at step210. The additional layers may include any suitable materials or layers, such as, for example, image layers, sealing layers, thermoplastic layers, metal layers, conductive layers, non-conductive layers, and/or any other suitable layers. Although embodiments are discussed herein with respect to a single card core2, a single credential core, and a single credential card, it will be appreciated that multiple card cores2, credential cores, and/or credential cards may be formed simultaneously using any suitable process. Various processes for forming a credential card compatible with the metal card cores disclosed herein are disclosed in, for example, U.S. Pat. Appl. Pub. No. 2016/0152815, published Jun. 2, 2016, and is incorporated by reference herein in its entirety. A credential card including a card core, such as a card core2, disclosed herein can be formed using any suitable method. For example, in various embodiments, a credential card including a card core2may be formed using a cold laminate process, injection molding, milling, laser cutting, water-jet processes, etc.

At optional step114, a portion of each layer positioned above the contact pads24a,24bmay be removed to expose the contact pads and a second circuit element16bmay be coupled to the contact pads24a,24b. The contact pads24a,24bmay be exposed using any suitable process, such as, for example, etching, drilling, milling, etc. A portion of the credential card or card core may be removed around the contact pads24a,24bsufficient to allow a second circuit element16b, such as a direct contact SoC element32, to be positioned with a surface parallel to a plane defined by a surface of the credential card and/or the card core (as illustrated inFIG.3).

FIG.6illustrates a card core2ahaving a sinuous line discontinuity10aincluding a first straight line segment36aand a second straight line segment36bdefining a single flexible finger22, in accordance with some embodiments. The card core2ais similar to the card core2discussed above, and similar description is not repeated herein. The sinuous line discontinuity10agenerally defines a curved path (e.g., a notch or channel) extending from an inner edge of the cutout8to an outer edge12aof the core card2a

FIG.7illustrates a card core2bhaving an sinuous line discontinuity10bincluding an extended straight line portion42aand a truncated straight line portion42b, in accordance with some embodiments. The card core2bis similar to the metal card core2discussed above in conjunction withFIG.5, and similar description is not repeated herein. The card core2bincludes a sinuous line discontinuity10bcoupled to a lower portion of the second portion8bof the cutout8. A first substantially straight portion42aof the discontinuity10bhas a longer length as compared to a first substantially straight portion36aof the sinuous line discontinuity10aof the card core2and a second straight portion42bhas a substantially shorter length. The sinuous line discontinuity10bfurther includes a first portion38aextending from the cutout8and a second portion38bextending from the first edge12a, each disposed at a non-parallel and non-perpendicular angle with respect to each of the edges12a,12b,14a,14bof the card core2b.

FIG.8illustrates a card core2cincluding a straight line discontinuity44, in accordance with some embodiments. The card core2cis similar to the card cores2-2bdescribed above, and similar description is not repeated herein. The card core2creplaces the sinuous line discontinuity10with a straight line discontinuity44extending from an edge9of the cutout8to an edge12aof the card core2c. The straight line discontinuity44includes a thickness selected to effectively isolate a first side20aof the discontinuity44from a second side20bwithout substantially weakening the structure of the card core2. For example, in various embodiments, the straight line discontinuity44includes a width (e.g., distance from first side20ato second side20b) of at least 300 microns, at least 500 microns, at least 700 microns, 300-900 microns, and/or any other suitable width.

FIG.9illustrates a card core2dincluding a cutout58extending to an edge14aof the card core2d, in accordance with some embodiments. The card core2dis substantially similar to the card core2described above, and similar description is not repeated herein. The card core2dincludes a body52defining a cutout58including a first portion58aand a second portion58b. The body52extends substantially defined by a first short edge12a, a second short edge12b, a first long edge14a, and a second long edge14b. The cutout58extends from the first long edge14ainto the body52such that the cutout58defines a portion of the first long edge14aof the card. As discussed above with respect to card core2, one or more circuit elements may be positioned within any portion of the cutout58such that a gap (seeFIGS.2-3) sufficient to electrically isolate the circuit element from the card core2dis maintained.

In the illustrated embodiment, the cutout58includes a first portion58ahaving a first rectangular geometry extending between a first edge portion60aof the card core2dand a second edge portion60band a second portion58bhaving a second rectangular geometry continuous with the first portion58a. Although specific embodiments are illustrated, it will be appreciated that the cutout58can include any number of portions defining any number of geometries, and such embodiments are within the scope of this disclosure.

In some embodiments, a portion of the cutout58, such as the first portion58a, defines an embossable area62. The embossable area62includes a portion of a card core2dand/or a finished credential card including the card core2dthat may be subjected to known embossing techniques. For example,FIG.10illustrates a finished credential card70(i.e., a credit card) including an overlay layer72and an embossing74disposed within the embossable area62.FIG.10further illustrates a circuit element76, such as a direct contact SoC element, disposed within the second portion58bof the cutout58. The finished credential card70may be formed using any known technique, such as, for example, the method100discussed above in conjunction withFIG.4.

Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.