The present invention is a method of providing a transaction card with the ability to transmit electronic information (e.g., credit card, financial instrument, identification card, security card, and the like including those with Europay, Mastercard and Visa chip—EMV chip) used to provide information about an account, the user or bearer, the card or other information including the ability to authenticate the account, user, bearer, card or associated an event or transactions card
Most individuals and companies own or possess several different cards such as credit cards, debit cards, automatic teller machine (ATM) cards, employee identification cards, student identification cards, building access cards, club membership cards, airline frequent flyer cards, grocery store discount cards, department store account cards, telephone cards, rental cards, public transportation fare cards, and the like. To facilitate the operation and utility of these cards, one or more magnetic stripes can be used for storing data such as the bearer's identity or account information.
The magnetic stripe (e.g., mag stripe) or other magnetic area of the card typically stores digital data using magnetic based particles on a band of a magnetic material placed on the card. Typically, the magnetic stripe (e.g., swipe card or magstripe), can be read (e.g., data retrieve from the magnetic stripe) by swiping past a magnetic reading head or placing the magnetic stripe in proximity to a reader. As the technology has progressed, several International Organization for Standardization standards, ISO/IEC 7810, ISO/IEC 7811, ISO/IEC 7812, ISO/IEC 7813, ISO 8583, and ISO/IEC 4909, have provided definitions of the physical properties of the card, including size, flexibility, location of the magstripe, magnetic characteristics, and data formats. For example, U.S. Pat. No. 3,294,956 discloses a mechanism for positioning and referencing a magnetic ledger card so that information may be read from or written on to a magnetic stripe thereon by a movable magnetic head which traverses the ledger card.
A magnetic stripe can include magnetic particles suspended in a resin where the particles can be applied directly to the card or made into a stripe on a plastic backing which is applied to the card. The material used to make the particles defines the Coercivity (see below) of the stripe. Standard low coercivity stripes use iron oxide as the material to make the particles, high coercivity stripes are made from other materials like barium ferrite. These materials are mixed with a resin to form a uniform slurry which is then coated onto a substrate. In the case of a credit card or similar application the slurry is usually coated onto a wide plastic sheet and dried. The plastic sheet is then sliced into the stripe width and applied to the card during the card manufacturing process. The application of the stripe (e.g., cut sheet) includes lamination, hot-stamp, and cold-peel. All of these are a three-step application process and require making the sheet, making the stripe, and applying the stripe of the card. In another traditional method of applying magnetic material to a case, a magnetic slurry is painted on the card.
A significant disadvantage with the current technology in adding magnetic stripes to the card (e.g., substrate) is that the application of the magnetic stripe to a card can lead to error and premature wear and failures. Further, the amount of magnetic material that can be placed on a card is limited to the thickness of the applied stripe. It is undesirable for the magnetic stripe to cause a ridge or to be raised too much above the card substrate as this disadvantage prevents the face of the card from being planer. Further, it is shown that if the magnetic stripe is exposed to a magnetic field, the information on the magnetic stripe can be damaged and even erased. In one study, it was discovered that if a D82 magnet was rubbed against a traditional credit card at a distance of 0.02 inches or less, the magnetic stripe ceased functioning. It would be advantageous to have a magnetic stripe that can be read by a reader while having a separation from the outer most surface of the card.
Cards, including cards, have evolved from credit cards and other cards having raised alphanumeric characters built included on the card into cards having embedded chips, EMV chip and other electronics. Typically, a card has the footprint of a credit card. The housing of the card typically includes electronics that can store information thereby making the card “smart” in that it can store its data and applications. Some cards have basic data processing functionality by adding processors.
Cards can store personal information, store digital currency, verify identity and any combination thereof. Cards have advanced from cards that only include raised characters, magnetic strips or barcodes that rely on the card processing of other networks to function.
Consumers have shown that metal financial cards are desirable both in the look and feel of the card. Metal cards, with added weight and the sounds when contacting a surface, have become a symbol of status and seem to be more attractive to consumers that desire leading edge technologies. There is also a perception that a metal card represents a higher quality, credit card issuer. Further, financial institutions are consistently seeking new solutions for customer as well as points of differentiation with their competitors. Offering metal cards with these financial institutions brand is one vehicle used by these financial institutions. As stated, the current production of metal cards creates challenges and can be a complicated process. For example, U.S. Pat. No. 7,530,491 shown a card that include a core layer that is thermoplastic material which could include PVC, PET copolymer, or other substrate. There is then a metal laminated to one or both sides of the core layer. The card includes a pocket that can be filled with a panel. The fill panel be adhered to the pocket. This this patent described a metal card, it does not provide for a method of removing the inefficiencies of information transmission (e.g., wireless transmission) as the fill panel is made using the method of the card which includes a metal layer throughout.
Therefore, it is an object of the present invention to provide for a metal or mostly metal financial card that allows for contactless payment.
It is another object of the present invention to provide for a metal card having contactless payment using EMV chips.
The above objectives are accomplished by providing a method of providing a contactless card comprising a substrate; creating a slit, that, in one embodiment, can be at least 250μ in thickness into a substrate. The slit can be useful to counteract the shielding created when a conductive substrate is present. The slit can redefine the flow of electrons in, what is effectively a Faraday cage, created by a conductive substrate. The slit can reduce or prevent the substrate from interfering with the EMV chip and allow the conductive material to act as an antenna. The reconfiguring and/or redirecting of electrons can occur when using a number of substrate materials including brass, silver, gold, aluminum, molybdenum, titanium, tungsten, other metals, and any combination. The slit can be filled with a malleable filler material. The filler material can be a polymer, ceramic, composite, plastic, and any combination. The substrate and the filler material can be coated or painted. The method can include attaching a chip to the substrate. The coating or painting can be color, metallic or both. The method can strengthen the slitted area and substrate by using the filler material.
The filling of the slitted area can be force cured at a higher temperature than the temperature where filling occurs. This filling process can be performed multiple times so that the filler material, in the event of shrinkage, completely fills the slit and results in a planar surface. Repeating the filling and curing process assists with a complete fill of the slit and can assist with providing a flush and level surface defined by the substrate and filled slit. The slit can be cut into the substrate at a depth of 20μ or less in one embodiment. A chip can be inserted in the substrate. Testing can be performed to determine if the card can be read by a reader.
The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
With reference to the drawings, the invention will now be described in more detail.
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The non-conductive filler material can be applied in, on, or over the card and its slit. The filler material can be dielectric. The process of providing the filler material can include processing or treating a portion of or the entire card using an injection machine, manual application, additive manufacturing, phase change application, of both. The process of providing the filler material can include rolling, spraying, printing, spreading, or self-leveling the filler material into the slit. The filler material, once applied to the card and inserted into the slit, can be cured at a temperature at least one-degree Fahrenheit more than the application temperature. The filler material can then be force cured. The process of applying filler material can be through multiple applications. The filler material can be cured by forced air or heat which can strengthen the filler material as well as bond the filler material to the substrate creating a solid composite. The composite can receive printing or can be coated with paint or other coating. Application of a coating or paint can include curing the coating or paint to obscure the filled slit.
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The coating or paint that can be applied over the filled slit and surrounding area can be on a single or multi-phase process. The application of the coating or paint can involve a vacuum or physical vapor deposition which provide for an aesthetic appearance of metal or metallization. The filling of the slit and application of the coating and the paint can strengthen the substrate and card. The filled slit with a coating or paint allows for an atheistically smooth surface while also allowing the transmission of data from the card chip to a reader to be successful even when an insulating substrate or layer (e.g., metal substrate) is used.
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In one embodiment, the additive manufacturing process can include the application of two material to form the substrate with a magnetic stripe or magnetic area. The additive manufacturing process can include a first set of passes where substrate material is added and a first portion 60 of the substrate is created. The additive manufacturing process can be used to create a second portion 62 that can have substrate material 62a and magnetic material 62b deposited on the first portion of the substrate 60. The magnetic material can include magnetic particles configured to allowing recording of information in a range of 25 to 500 bits per inch. There can be one or more stripes placed on the substrate. The substrate, with magnetic material can be coated and painted in one embodiment.
In one embodiment, a third portion 64 can be manufactured through additive manufacturing that can include adding indicia 66 such as alpha numeric characters, figures, shapes, images, and any combination to the substrate. For example, the additive manufacturing process can cause an account number to be placed on the substrate in raised numbers or the substrate can be created with material absent so that the absence of material causes numbers to appear debossed or imbedded into the substrate. The indicia can be an account number that can be separate din more or more groupings 70a through 70d. The magnetic portion 72 made with additive manufacturing place placing the magnetic material during or after the substrate is made can be on one side of the substrate with the indicia manufactured on the other side of the substrate. The indicia can be a custom image of graphic that is supplied by a user and can allow each card to be customized by the user.
In one embodiment, the concave or convex surface of the filler material is not perceivable to the human touch and provides for an aesthetic appearance and feeling. The multiple filling and curing steps allow for the filler material to be generally planer with the surface of the substrate an account for expansion and shrinkage of the filler material during the manufacturing process.
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The resin can include the reaction product of Bisphenol A and epichlorhydrine (having an average molecular weight <700) and can be greater than 50% of the resin. The resin can include neodecanoic acid, 2,3-epoxypropyl ester and be in the range of 0.5% to 10% of the resin. The filler material can include the resin and a ferromagnetic material added to the material to provide for a ferromagnetic resin that can be added to the slit.
The resin can be applied in one process, allowed to cure, or partially cure and an additional resin applied in a second process. When cured to dry, the resin is flush with the horizontal edge of the card or plate. When painted, the card or plate appears flat and of a single material rather than metal with resin.
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It is understood that the above descriptions and illustrations are intended to be illustrative and not restrictive. It is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims. Other embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventor did not consider such subject matter to be part of the disclosed inventive subject matter.
This application claims priority on U.S. Provisional Patent Applications 63/132,957 filed Dec. 31, 2020; 63/138,727 filed Jan. 18, 2021; 63/142,652 filed Jan. 28, 2021; and 63/224,616 filed Jul. 22, 2021 and 63/236,401 filed Aug. 24, 2021 all of which are incorporated by reference.
Number | Date | Country | |
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63236401 | Aug 2021 | US | |
63224616 | Jul 2021 | US | |
63142652 | Jan 2021 | US | |
63138727 | Jan 2021 | US |