Dual interface capacitive embedded transaction card

Abstract

The present invention discloses a dual interface capacitive embedded transaction card. The transaction card has a card periphery defined by first and second short sides and first and second long sides, and includes: a plurality of metal layers; an opening in at least one of the plurality of metal layers, the opening having a first edge, a second edge, and a third edge; and a discontinuity in at least the first of the plurality of metal layers, the discontinuity defining a path starting at an origin at the card periphery and terminating at an end point in the opening, wherein one of the end point or the origin is relatively closer to a line defined by the first long side of the card periphery than the other of the end point or the origin, and the path has a length greater than the shortest distance from the end point to a side of the card periphery containing the origin, wherein the short side of the card periphery has an area aligned with the first edge of the opening, and the origin is positioned on the card periphery outside the alignment area, wherein at least a portion of the discontinuity in the first metal layer is aligned with a non-discontinuity area of ​​the second metal layer.

Description

[0001] This application is a divisional application of the Chinese patent application filed on July 28, 2020, with application number 201980010545.1 and invention name “Dual-interface capacitor embedded metal card”. The international filing date of the parent application is January 23, 2019, and the international application number is PCT / US2019 / 014656.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Application No. 15 / 928,813, filed on March 22, 2018, and U.S. Application No. 62 / 623,936, filed on January 30, 2018, both of which are incorporated herein by reference in their entirety. Background Art

[0004] Cards such as identification cards, transponder cards, and transaction cards such as credit cards, debit cards (sometimes also referred to as smart cards) are well known in the art, and some embodiments thereof may include one or more metal layers. An exemplary such card is shown in U.S. Patent No. 8,725,589, which is incorporated herein by reference. It is also well known to embed microchips or payment modules in transaction cards, including in metal cards. Some embedded payment modules (referred to as "dual interface" modules) have: contacts disposed on one side of the card and configured to interface with a card reader; and a radio frequency identification (RFID) antenna for inductive communication with the card reader. In a metallic environment, such as a metal card, it may be desirable to provide an enhanced antenna or amplifier to improve the performance of the communication interface with the card reader.

[0005] In particular, it is known to use the metal frame of the card itself as such an antenna or amplifier, with the metal housing surrounding the payment module chip having a discontinuity or "slot" in the metal. U.S. Patent No. 8,608,082 to Le Garrec et al. (the '082 patent) and U.S. Patent No. 9,812,782 to Finn et al. (and other patents), incorporated herein by reference, disclose metal cards having such discontinuities in the form of slots extending from the mounting location of the RFID chip in the card to the peripheral edge of the card. The concept of a metallic, card-shaped, contactless antenna with a slot for RFID signal amplification in a metallic environment is also generally described in literature such as "A Metallic RFID Tag Design for Steel-Bar and Wire-Rod Management Application in the Steel Industry," Progress in Electromagnetic Research Symposium (PIER), Vol. 91 (2009).

[0006] The '082 patent characterizes the metal frame of the card as an amplifier for amplifying the gain of a near field communication antenna electrically connected to a microcircuit associated with a payment module, the amplifier comprising a "generally annular shaped conductive element electrically insulated from the microcircuit and from the antenna," which in some embodiments forms a loop that is broken at least once.

[0007] Finn's patent refers to the payment module as a "transponder chip module (TCM) including an RFID chip (IC) and a module antenna," and describes the amplifier formed by the card body as a "coupling frame" having "electrical discontinuities including slits or non-conductive strips."

[0008] Regardless of which term is used, metal "slit" cards may have some disadvantages. In particular, embodiments in which a single slit extends from the midpoint of one edge of the module bag to the periphery of the card on a straight horizontal line that is the shortest path from the bag to the periphery provide little resistance to bending of the card at the discontinuity. Metal cards may still have one or more layers on the metal layer. For cards in which one or more layers are plastic, the plastic may begin to wear or turn white due to such bending. Therefore, there is a need in the art for a design that provides better resistance to bending of the card and potential wear caused thereby. Although Finn has proposed some alternative configurations, there is still a need in the art for configurations that provide improved functionality and aesthetics. Summary of the invention

[0009] One aspect of the invention includes a transaction card comprising: a metal layer; an opening in the metal layer for receiving a transponder chip module; and at least one discontinuity. The discontinuity comprises a gap extending from a front surface of the metal layer to a rear surface of the metal layer and having a certain width. The discontinuity extends from an origin on the periphery of the card to an endpoint in the opening for the transponder chip. The card has greater resistance to bending than a card having a discontinuity with the same gap, wherein the endpoint and the origin are the same distance from a line defined by a first long side of the periphery of the card, but without one or more strengthening features. One strengthening feature comprises a single discontinuity, wherein one of the endpoint or the origin is positioned relatively closer to the first long side of the periphery than the other. Another strengthening feature comprises a plurality of discontinuities, each having a certain length, wherein less than all of the plurality of discontinuities extend from the periphery of the card to the opening. Another strengthening feature comprises a self-supporting non-metallic layer disposed on at least one surface of the card. Yet another strengthening feature comprises one or more ceramic reinforcing tabs disposed on one or both surfaces of the card surrounding the opening. The card may have one or any combination of the foregoing strengthening features.

[0010] Typically, the opening in the metal layer has a first edge that is parallel to and relatively closest to a first short side of the card periphery and aligned with a first portion of the card periphery. The second edge of the opening is parallel to and relatively closest to the first long side of the periphery. The third edge of the opening is parallel to and relatively closest to the second long side of the periphery. The first edge of the opening is relatively closer to the short side of the periphery than the second edge is to the long side of the periphery. The second edge of the opening is relatively closer to the first long side of the periphery than the third edge is to the second long side of the periphery of the card. The edge of the opening defines an angle. The opening can be a stepped opening having a first opening area defined in a first surface of the card and a second opening area defined in a second surface of the card, wherein the first opening area is larger than the second opening area.

[0011] Another aspect of the invention includes a transaction card having a metal layer, an opening in the metal layer, and a discontinuity, wherein the discontinuity defines a path wherein one of a terminal point or an origin is positioned relatively closer to a first long side of a periphery than the other.

[0012] In some embodiments, the short side of the card periphery has an area aligned with the first edge of the opening, and the origin is located on the periphery outside the aligned area. The end point can be located at a corner of the opening, or relatively closer to an adjacent corner defined by a common edge than a corner.

[0013] In some embodiments, the discontinuous path includes at least two 90 degree or greater changes in direction. At least a portion of the discontinuous path may define a step-like geometry including more than two 90 degree changes in direction, or a portion of the discontinuous path may define a sawtooth-like geometry including more than two changes in direction greater than 90 degrees, or a combination thereof. In embodiments where the discontinuous path includes at least one change in direction greater than 90 degrees and at least one change in direction of 90 degrees, the path may have a micro-step-like geometry and a macro-sawtooth-like geometry, including at least a first plurality of more than two 90 degree changes in direction, resulting in a first change in direction greater than 90 degrees; and a second plurality of more than two 90 degree changes in direction, resulting in a second change in direction greater than 90 degrees. A discontinuity with a step-like geometry may have a step height greater than the stroke, and vice versa. A discontinuity with a step-like geometry may have a radius of curvature at each change in direction.

[0014] In some embodiments, the interrupted path has at least one segment of a curved geometry, including embodiments in which the interrupted path has one or more changes in direction greater than or equal to 90 degrees, wherein at least one change in direction has a curved geometry. The interruption can have, for example, a sinusoidal shape including at least two changes in direction greater than 90 degrees.

[0015] The discontinuity may extend from the first short side of the periphery to the second edge of the opening, or from the first or second long side of the periphery to the opening. It may be said that the first edge and the second edge of the opening define a first corner of the opening, and the first edge and the third edge of the opening define a second corner of the opening. In some embodiments, the discontinuity extends from the first edge at a position relatively closer to the second corner than the first corner, and terminates at the short side of the periphery at a position relatively closer to the first corner than the second corner. In other embodiments, the discontinuity extends from the opening at a position relatively closer to the first corner than the second corner, and terminates at the short side of the periphery at a position relatively closer to the first corner than the second corner.

[0016] The card may include a transponder chip module disposed in the opening, in which case the metal layer includes an enhanced antenna or amplifier for the transponder chip module. The card may have a first non-metallic layer, such as a plastic or ceramic layer, disposed on a first surface of the metal layer. The ceramic layer may include a ceramic coating, wherein the gap defined by the discontinuity is at least partially filled with the ceramic coating. The non-metallic layer may include a decorative layer comprising one of wood or leather. The second non-metallic layer may be disposed on the second surface of the metal layer. In one embodiment, the first non-metallic layer includes a ceramic layer and the second non-metallic layer includes a plastic layer. The discontinuity may be optically visible from one or both surfaces of the card, or may be optically invisible from at least one surface of the card.

[0017] Another aspect of the invention includes a transaction card comprising a metal layer having a front surface and a back surface; and a plurality of discontinuities in the metal layer, wherein less than all of the plurality of discontinuities extend from the periphery to the opening. At least one of the plurality of discontinuities may have a length equal to the shortest length from the opening to the periphery. At least two of the plurality of discontinuities may be parallel to each other.

[0018] Another aspect of the invention is a method for manufacturing a transaction card as described herein. The method comprises: providing a metal layer; creating an opening in the metal layer, the opening being sized to accommodate a transponder chip module; creating a discontinuity, wherein one of the endpoint or the origin is positioned relatively closer to the long side of the periphery than the other; and arranging the transponder chip module in the opening. The discontinuity may be formed before creating the opening for the transponder chip module. The method may comprise creating one or more discontinuities having endpoints positioned within the boundaries of the opening. The method may comprise creating a stepped opening having a first portion having a first opening area and a second portion having a second opening area, the second opening area being larger than the first opening area. The method may comprise creating the first portion of the opening from the front surface of the card, and creating the second portion of the opening from the rear surface of the card. The discontinuity may be formed using a laser. The method may further comprise at least partially filling a gap defined by the discontinuity with a non-metallic material. At least one non-metallic layer may be provided on the front or rear surface of the metal layer, for example by adhesive bonding, or wherein the non-metallic layer comprises a ceramic layer obtained by spraying a ceramic layer on the metal layer. Spraying the ceramic layer onto the metal layer may include at least partially filling the gap with the ceramic coating.

[0019] Another aspect of the invention may include providing a card as described herein having a non-metallic layer, the non-metallic layer including a ceramic layer having a color, and another aspect of the invention also includes creating one or more permanent marks on the ceramic layer with a laser having a color different from the color of the ceramic layer. Creating one or more permanent marks on the ceramic layer may include removing the upper ceramic layer to expose a lower layer having a different color, which may be a metal layer or a lower ceramic layer having a different color than the outermost ceramic layer.

[0020] Another aspect of the invention comprises a card with a metal layer as described herein, the card having at least one non-metallic layer comprising a self-supporting layer, such as a self-supporting layer comprising polyimide or a glass fiber reinforced layer comprising an epoxy resin such as FR4. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1A is a schematic illustration of a machine tool path for creating discontinuities in a metal layer relative to upper and lower boundaries of a transponder chip opening in the metal layer.

[0022] Figure 1B The basis for observation from the front, top, and right side Figure 1A Perspective illustration of the created metal layer showing the openings and discontinuities before inserting a transponder chip into the transponder chip opening.

[0023] Figure 1C After the payment module is inserted, Figure 1B A perspective view illustration of an exemplary metal layer of a card with discontinuities and openings depicted.

[0024] Figure 2 yes Figure 1C A plan view illustration of the front surface of a card.

[0025] Figure 3 yes Figure 1C A floor plan illustration is shown on the left side of the card.

[0026] Figure 4 yes Figure 1C The floor plan illustration is on the right side of the card.

[0027] Figure 5 yes Figure 1C A plan view illustration of the top side of the card.

[0028] Figure 6 yes Figure 1C A plan view illustration of the underside of the card.

[0029] Figure 7 yes Figure 1C FIG. 1 is a plan view illustration of the rear surface of the card.

[0030] Fig. 8A is a schematic illustration of a machine tool path that is discontinuous relative to the upper and lower boundaries of the transponder chip opening for another exemplary card embodiment.

[0031] FIG. 8B to FIG. 8F They are respectively Fig. 8A Perspective and plan view illustrations of the front, top, left, and back surfaces of a discontinuous exemplary card depicted.

[0032] Fig.9A is a schematic illustration of a machine path having discontinuities in a step-like geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0033] FIG. 9B to FIG. 9F They are respectively Fig.9A Perspective and plan view illustrations of the front, top, left, and back surfaces of a discontinuous exemplary card depicted.

[0034] Fig. 10A is a schematic illustration of a machine path with a curved geometric discontinuity relative to the upper and lower boundaries of a transponder chip opening according to another exemplary embodiment.

[0035] FIG. 10B to FIG. 10F They are respectively Fig. 10A Perspective and plan view illustrations of the front, top, left, and back surfaces of a discontinuous exemplary card depicted.

[0036] Fig.11A is a schematic diagram of a machine tool path having discontinuities with a sawtooth-like geometry relative to the upper and lower boundaries of the transponder chip opening for another exemplary card embodiment.

[0037] FIG. 11B to FIG. 11F They are respectively Fig.11A Perspective and plan view illustrations of the front, top, left, and rear surfaces of the discontinuous exemplary card depicted in FIG.

[0038] 12 is a schematic illustration of a machine tool path with micro-step and macro-serrated geometry discontinuities relative to the upper and lower boundaries of the transponder chip opening for another exemplary card embodiment.

[0039] FIG. 12B to FIG. 12F They are Fig. 12A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of an exemplary card with discontinuities depicted in FIG.

[0040] Fig.13A is a schematic illustration of a machine tool path having discontinuities in a sawtooth-like geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0041] FIG. 13B to FIG. 13F They are respectively Fig.13A 2. Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0042] Fig.14A is a schematic illustration of a machine tool path with discontinuities having a curved sinusoidal geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0043] FIG. 14B to FIG. 14F They are respectively Fig.14A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0044] Fig.15A is a schematic illustration of a machine tool path having discontinuities with curved sinusoidal geometry relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0045] FIG. 15B to FIG. 15F They are respectively Fig.15APerspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0046] Fig.16A is a schematic illustration of another exemplary card embodiment, a machine tool path having discontinuities of curved sinusoidal geometry relative to the upper and lower boundaries of the transponder chip opening.

[0047] FIG. 16B to FIG. 16F They are respectively Fig.16A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0048] Fig.17A is a schematic illustration of a machine tool path having discontinuities with curved sinusoidal geometry relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0049] FIG. 17B to FIG. 17F They are respectively Fig.17A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0050] Fig.18A is a schematic illustration of a machine tool path having discontinuities with a curved sinusoidal geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0051] FIG. 18B to FIG. 18F They are respectively Fig.18A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0052] Fig.19A is a schematic illustration of a machine path having discontinuities in a step-like geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0053] FIG. 19B to FIG. 19F They are respectively Fig.19A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0054] Fig. 20A is a schematic illustration of a machine tool path having a single step-like geometric discontinuity relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0055] FIG. 20B to FIG. 20F They are respectively Fig. 20A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0056] Fig.21A is a schematic illustration of a machine tool path having a single step-like geometric discontinuity relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0057] FIG. 21B to FIG. 21F They are respectively Fig.21A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0058] Fig.22A is a schematic illustration of a machine tool path extending from an opening of the card to a discontinuity on the bottom side of the card relative to upper and lower boundaries of the transponder chip opening for another exemplary card embodiment.

[0059] FIG. 22B to FIG. 22F They are respectively Fig.21A 2. Perspective view illustrations (B) and plan view illustrations of the front surface (C), bottom side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0060] Fig.23A is a schematic illustration of a machine tool path extending diagonally from an opening of the card to a discontinuity near the lower left corner of the card relative to upper and lower boundaries of a transponder chip for another exemplary card embodiment.

[0061] FIG. 23B to FIG. 23F They are respectively Fig.23A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0062] Fig.24A is a schematic illustration of a machine tool path also extending diagonally from an opening of the card to a discontinuity near the lower left corner of the card relative to the upper and lower boundaries of the transponder chip for another exemplary card embodiment.

[0063] FIG. 24B to FIG. 24F They are respectively Fig.24A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0064] Fig.25Ais a schematic illustration of a machine tool path of a plurality of discontinuities relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0065] FIG. 25B to FIG. 25F They are respectively Fig.25A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0066] Fig.26A is a schematic illustration of a machine tool path of a plurality of discontinuities relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0067] FIG. 26B to FIG. 26F They are respectively Fig.26A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0068] Fig.27A is a schematic illustration of a machine tool path of a plurality of discontinuities relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0069] FIG. 27B to FIG. 27F They are respectively Fig.27A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0070] Fig.28A is a schematic illustration of a machine tool path of a plurality of discontinuities relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0071] FIG. 28B to FIG. 28F They are respectively Fig.28A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0072] Fig.29A is a schematic illustration of a machine tool path of exemplary discontinuities relative to upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0073] FIG. 29B to FIG. 29F They are respectively Fig.29A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0074] Fig. 30Ais a schematic illustration of a machine tool path of an exemplary discontinuity having a curved geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0075] FIG. 30B to FIG. 30F They are respectively Fig. 30A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0076] Fig.31A is a schematic illustration of a machine tool path of an exemplary discontinuity having a curved step-like geometry relative to the upper and lower boundaries of a transponder chip opening for another exemplary card embodiment.

[0077] FIG. 31B to FIG. 31F They are respectively Fig.31A Perspective view illustrations (B) and plan view illustrations of the front surface (C), top side (D), left side (E), and back surface (F) of the discontinuous exemplary card depicted in FIG.

[0078] Fig.32 is a cross-sectional illustration of an exemplary card embodiment showing exemplary optional layers above and below the metal layer.

[0079] Fig.33 is a cross-sectional illustration of an exemplary card embodiment showing a surface coating with various exemplary indicia and engravings.

[0080] Fig.34 is a cross-sectional illustration of another exemplary card embodiment showing a discontinuity partially filled with a surface coating.

[0081] Fig.35A is a plan view of the front surface of an exemplary card having a discontinuity and an exemplary pocket for receiving a reinforcement tab.

[0082] Fig.35B is from before accommodating the reinforcement tab Fig.35A A perspective view of the card looking at the front left side.

[0083] Fig.35C is from Fig.35A Exploded perspective view of the front left lower corner of the card showing the placement of the reinforcement tab.

[0084] Fig.35D Yes Fig.35C A perspective view of the isolated front tab is depicted.

[0085] Fig.35E Yes Fig.35C A perspective view of the isolated rear tab is depicted. DETAILED DESCRIPTION

[0086] Figures 1A to 7 A portion of an exemplary transaction card or card 100 is shown having a left side 104 (also Figure 3 depicted in the middle), right side 106 (also Figure 4 ), top side 108 (also depicted in Figure 5 ) and bottom side 102 (also depicted in Figure 6 1 and 10. The card periphery 101 is defined by a left side 104 and a right side 106. The top side 108 and the bottom side 102 are parallel to each other. The sides 104 and 106 may be referred to as "relatively short" sides, and the sides 108 and 102 may be referred to as "relatively long" sides. Figure 1C The portion of the card shown in FIG. 1 is a card having a front surface 112 (also shown in FIG. Figure 2 ) and the rear surface 114 (also depicted in Figure 7 It should be understood that the terms "front" and "back" are used herein to distinguish between opposing surfaces, and the use of these terms is not intended to have a specific meaning. Similarly, the terms "left and right" and "top and bottom" are used to refer to the sides that form the periphery of the card, and these terms are used from, for example, Figure 2 The front surface of the card is depicted at an angle, but again, these terms are for ease of description only. Similarly, the term "side" is used herein to refer to the side forming the periphery of the card, and the term "edge" is used to refer to the edge of the opening boundary, but the use of these terms is intended only for distinction and no specific meaning is given to the terms used.

[0087] like Figure 1B , Figure 1C and Figure 2 As depicted, opening 120 in metal layer 100 is sized to accommodate a transponder chip module 121 (eg, Figure 3 The details of the transponder chip module are not a claimed feature of the present invention and are shown for illustrative purposes only. Although an 8-pin module is shown, the transponder may have fewer or more contacts, such as a 6-pin module. Those skilled in the art will recognize that any number of different transponder chip designs are available and may be used in the exemplary card.

[0088] As in Figure 1B, the opening has a left edge 124 that is parallel to and relatively closest to the left short side 104 of the card periphery 101, a second edge 128 that is parallel to and relatively closest to the top side 108 of the card periphery 101, and a third edge 122 that is parallel to and relatively closest to the bottom side 102 of the card periphery. The left edge 124 is relatively closer to the left side 104 of the card periphery than the top edge 128 is to the top side 108 of the periphery, and the top edge 128 is relatively closer to the top side 108 of the periphery than the bottom edge 122 is to the bottom side 102 of the card periphery. The edges of the opening 120 define corners (e.g., an upper left corner 125 formed by the edge 124 and the edge 128, and a lower left corner 123 formed by the edge 124 and the edge 122).

[0089] The discontinuity or slot 130 in the metal layer 100 comprises a gap in the metal layer extending from the front surface 112 to the back surface 114 of the metal layer 100. The terms "discontinuity" and "slot" are used interchangeably herein. The discontinuity defines a path starting from an origin (O) at the periphery of the card and terminating at a termination point (T) at the periphery of the opening. Figures 1A to 1C In the embodiment shown, the endpoint is positioned closer to corner 125 than to adjacent corner 123 defined by common edge 124. Here, most, if not all, other inventive embodiments show the endpoint being positioned closer to one corner than to the other corner defined by common edge. This is in contrast to prior art designs, which show the slit terminating at a location midway between adjacent corners 123 and 125.

[0090] like Figure 1A and Figure 1B As depicted, the opening and discontinuity reflect the intermediate steps in the manufacture of the card. As depicted, the opening 120 is a stepped pocket opening that defines an entire area having an outer boundary 144 and an inner boundary 146. The upper portion of the stepped pocket opening (leading to the front surface of the card) has an opening area defined by the outer boundary 144. The lower portion of the bag (leading to the rear surface of the card) has an area defined by the inner boundary 146, wherein the area of ​​the lower portion of the bag is less than the area of ​​the upper portion of the bag. The wall along the thickness direction of the card between the inner boundary and the outer boundary defines a ledge 147, which is between the inner boundary and the wall of the upper bag and has a surface parallel to the upper and lower surfaces of the card. It should be understood that, as used herein, the term "parallel" used in conjunction with any and all comparative features is intended to represent parallelism within a desired tolerance, but may include features that are not exactly parallel. The discontinuity is shown as having an endpoint E located on the inner boundary 146.

[0091] Figure 1A Shows Figure 1B and Figure 1C "Tool Path and Milling Boundary Map" of the card. Figure 1AThe discontinuity 130 is schematically reflected as a line showing the tool path of a cutter (eg, a laser) used to create the discontinuity. Figure 1A The line 130 in FIG. 1 extends past the origin O on the periphery of the card and past the endpoint E on the inner boundary of the opening. The manufacturing boundary lines corresponding to the opening show the locations of the inner boundary 146 and the outer boundary 144 of the upper and lower pockets produced by the pocket manufacturing process, which can be performed by a milling tool, an etching tool, a laser, etc. Sequentially, during the manufacturing process of the card, a discontinuity can first be cut in the metal layer, for example, using a laser, along a line including the origin O and the endpoint E, and the discontinuity can extend beyond the origin O and the endpoint E to ensure a complete cut through the metal layer. The upper and lower pockets are then milled. Therefore, although in Figure 1A The toolpath diagram of FIG. 1 shows that the endpoints of the discontinuity are located within the inner boundary 146, but in the case of Figure 1B In the complete metal layer shown, the discontinuity actually ends at point E at the inner boundary 146, but Figure 1C As seen from the front surface of the depicted card, the discontinuity is only visible at point T at the edge of the outer border 144, as the payment module is inserted into the opening. Since only the inner border 146 extends through the rear surface 114 of the metal layer, the discontinuity 130 extends to the end point E on the back of the card. It should be understood that the designs of the transponder chips shown herein illustrate only exemplary contact patterns, and that the present invention is not limited to any particular pattern. It should also be understood that although the present invention may be described in detail in detail, the present invention may be described in detail in detail. Figure 7 , the discontinuity 130, the inner border 146 and the rear surface of the module 126 are shown on the back side of the metal layer, but depending on the nature and opacity of the rear layer, the layers above the rear surface of the card may completely or partially obscure the visibility of the discontinuity, the transponder chip and the opening. Generally, the opening and transponder chip will usually be obscured from view by the opaque component or portion of the layer, but if viewed closely and if the optional rear layer of the card is not completely opaque, some portions of the discontinuity can be detected from the rear side. It will also be understood that the contacts on the top surface 127 of the transponder module are preferably flush with the outermost front surface of the card. If the metal layer is the top layer, the contacts will be flush with the front surface of the metal layer. However, if another layer such as a transparent plastic layer or ceramic layer is provided on top of the metal layer, then the contacts will not be visible. Fig.32 As shown, the contact portion will be mounted flush with the top layer 1200.

[0092] After the discontinuity is created, the opening may be cut by milling the lower portion first and then the upper portion, or vice versa. The lower portion may be milled from the rear surface of the card and the upper portion may be milled from the front surface of the card (although both portions may be milled from the front surface). In some embodiments, the non-conductive material may be arranged in the opening by any of the methods described in U.S. Patent No. 9,390,366, which is incorporated herein by reference. When the payment module is finally installed in the opening, the upper portion of the module rests on the ledge 147 and the integrated circuit on the back of the module is disposed in the lower portion. The geometry of the lower portion of the bag (e.g., by Figure 1A and Figure 1B The card's back surface (defined by the boundary 146 in the middle), and in particular its length (X dimension - parallel to the long sides 102, 108 of the metal layer) and width (Y dimension - parallel to the short sides 104, 106 of the metal layer) in a plane coextensive with the back surface of the card, have an impact on RF performance. For example, an acceptable performance range for a six-pin payment module may have X and Y dimensions preferably in the range of 3mm to 10mm, more preferably X=7.9mm to 8.9mm and Y=4.5mm to 6.0mm, and most preferably 7.9mm×5.3mm. For an 8-pin payment module, an acceptable performance range may have X and Y dimensions preferably in the range of 7mm to 10mm, and more preferably in the range of 7.5mm to 9.5mm. The size of the gap in the discontinuity may also affect performance, with the size of the gap preferably being less than 1mm, more preferably less than 0.5mm, and most preferably about 0.1mm, plus or minus 0.05mm. However, the present invention is not limited to any particular discontinuity gap size or dimension of the lower portion of the pocket. Figure 1A to Figure 2 In the depicted embodiment, the left side 104 of the card has an area 150 that is aligned with (e.g., coextensive and parallel to) the left edge 124 of the opening 120 / transponder module 121 (only in the Figure 2 1 ), and the origin (O) of the discontinuity is located on the card periphery 101 outside of region 150. In the embodiment shown in FIG. 1 , the endpoint is located at corner 125.

[0093] FIG. 8A to FIG. 31A Various other slot configurations are shown in , each of which can be characterized in a variety of ways and can have certain features. Fig. 8A , Fig.9AEach of the slits, etc., shows a manufacturing path or boundary line associated with each slit design. To illustrate the manufacturing path lines, the lines 802, 902, etc. corresponding to the depicted slits correspond to the tool path of a cutter (e.g., a laser) used to create the discontinuity. The manufacturing boundary lines corresponding to the openings show the inner boundaries (e.g., 804, 904) and outer boundaries (e.g., 806, 906) of the upper and lower pockets produced by the pocket manufacturing tool (which can be a milling tool, etching tool, laser, etc.). However, in each case, the finished metal layer of the card conforms to the following. FIG. 8B to FIG. 8F , FIG. 9B to FIG. 9F etc., where, for example Figure 8B 9B etc. show a front perspective view of the metal layer of each card, Figure 8C , Fig. 9C etc. shows the front surface diagram, Fig.8D , Fig.9D etc. show a top (or bottom) side view, Fig. 8E , Fig.9E etc. shows a left side view, and Figure 8F , Fig.9F It should be understood that one of the depicted top or bottom views is selected to show the side where the origin (O) of each discontinuity of the card is located, while one of the top or bottom views not shown is substantially the same as Figure 6 Likewise, the right side views of all the aforementioned embodiments are substantially the same as Figure 4 The side views shown are identical.

[0094] It should also be understood that FIG. 8A to FIG. 8F to FIG. 31A to FIG. 31F Only the metal layer of an exemplary card is shown. The metal layer may have one or more layers disposed on the front surface or the rear surface of the card, and each additional layer may cover the entire surface or only a portion of the surface. The metal layer itself may include a composite of multiple metal layers, including embodiments in which at least one layer includes a different metal than another layer. The additional layer may include, for example, any layer described in U.S. Published Patent Application Nos. US20150339564A1 and / or US20170316300A1, the entire contents of which are incorporated herein by reference. A preferred embodiment may include a ceramic coating on the front surface of the metal card and a plastic layer on the rear surface of the card.

[0095] Now refer to Fig. 8A For the depicted slot configuration, the origin (O) is positioned relatively closer to the line defined by the top side 108 than the endpoint (T). This feature is also true for the slot configuration shown in FIG. 1 in which the origin (O) is located on the top side 108. The location of the origin is relatively closer to the line defined by the top side of the periphery than the endpoint for at least Fig.9A , Fig. 10A , Fig. 12A , FIG. 14A to FIG. 17A , FIG. 19A to FIG. 21A , Fig. 30A and Fig.31A The same is true of the design depicted in . In other designs, such as FIG. 22A to FIG. 24A In the slot design shown in , the endpoint is located relatively closer to the line defined by the top side 108. The term "line defined by the top side" refers to an imaginary line in space along which the top side 108 is located. Because the card has rounded corners, the distance from the origin to the line defined by the top side 108 is measured from the intersection of the line defined by the top side 108 and the line defined by the left side 104, and the point is not actually physically presented as part of the metal layer with standard rounded corners. Therefore, in each of the aforementioned exemplary embodiments, one of the endpoint or the origin is positioned relatively closer to one long side of the periphery than the other. In other embodiments (e.g., Fig.11A , Fig.18A etc.), the end point and the origin can be positioned at approximately the same distance from the top side or the bottom side.

[0096] It should be understood that while the terms "origin" and "end point" represent one method of constructing a discontinuity, wherein the cut line begins at or before the origin and extends in the direction of the end point and beyond the end point as further described herein, the use of these terms does not imply a particular method of manufacture or direction of the cut used to form the discontinuity. Furthermore, while referred to as an "end point" as described elsewhere herein, the end point is merely the location where the discontinuity meets the opening on the top surface of the card, and the discontinuity actually extends further inward to the periphery of the opening in the rear surface of the card. Finally, while the front upper left portion of the card is typically the location of the contacts, and in connection therewith, consumers consider the "front" of the finished card to contain the card brand, card number, etc., it should be understood that in other embodiments, the contacts may be located in a mirrored position at the rear lower right portion of the card and provide equivalent functionality, wherein the discontinuity is positioned relative to the rear surface of the card similarly to being positioned relative to the front surface as depicted herein. Thus, as used herein, the "front" and "rear" surfaces of the card are relative to the placement of the transponder module, and do not necessarily reflect the traditional "front" or "rear" surfaces as these terms may be used by consumers receiving the final card. Of course, the location of the contacts is determined by the arrangement of the card reader that reads the card via the physical connection, and it will be appreciated that the location of the transponder chip relative to the periphery of the card is not limited by the present invention.

[0097] In certain embodiments, the discontinuous path includes at least two changes in direction of 90 degrees or greater. For example, Fig.9A , Fig.19A and Fig.31A A step-like design is shown in which the path is interrupted by multiple 90-degree changes in direction. Fig.9A , Fig.19A and Fig.31A In the illustrated embodiment, the step-like geometry has a step height (the vertical distance covered between adjacent horizontal segments) and a run length (the horizontal distance covered between adjacent vertical segments), wherein the step height is greater than the run length. In other embodiments not shown, the step height and run length may be equal or the run length may be greater than the step height. In the illustrated embodiment, the step height and run length of each step are approximately equal, but in other embodiments, the step height and run length may be different in at least one step relative to other steps in a series of steps.

[0098] Fig.11A and Fig.13A A sawtooth geometry is shown, wherein the discontinuous path makes multiple changes of direction greater than 90 degrees. Fig. 12A An intermittent path having a micro-step-like geometry and a macro-sawtooth-like geometry is shown, including at least: a first plurality of more than two 90-degree direction changes, resulting in a first direction change greater than 90 degrees; and a second plurality of more than two 90-degree direction changes, resulting in a second direction change greater than 90 degrees. Again, although shown with each "tooth" having substantially equal dimensions in the sawtooth-like geometry, the invention is not limited to such a geometry.

[0099] The interrupted path may also have at least one curved geometric section. Fig. 10A A substantially curved geometry is shown in , but the curved design may also have one or more changes in direction greater than or equal to 90 degrees, wherein at least one of the changes in direction has a curved geometry. FIG. 14A to FIG. 18A The illustrated embodiment shows such a feature, wherein Fig.14A to Fig.16A The discontinuous paths shown in each have a sinusoidal shape for at least a portion of the path, the sinusoidal shape including at least two changes in direction greater than 90 degrees.

[0100] Although the paths shown in FIGS. 14 to 16 are generally sinusoidal in nature, the paths shown in FIGS. 17A to 17B are generally sinusoidal in nature. Fig. 17C As shown, a curved path with multiple direction changes may also have a portion where a direction change of more than 180 degrees is completed, followed by a subsequent direction change of more than 180 degrees. FIG. 17A to FIG. 17C As shown in , the size of each segment that includes a 180 degree change in direction can vary over the length of the path from a relatively smaller segment 1712 to a relatively larger segment 1714.

[0101] Fig.31AThe path in depicts a segment of curved geometry within a step architecture, including a radius or fillet instead of a right angle for each 90 degree change in direction. Such a path can make the cutting tool faster to operate and / or more aesthetically pleasing than an embodiment with a sharp change in direction.

[0102] In some embodiments, for example, FIG. 15A to FIG. 18A As shown in , the end point of the interruption can be located on the top edge opening, and the origin is located on the left side of the card. In other embodiments, for example, Figures 1A to 7 and FIG. 22A to FIG. 22F As shown in , the discontinuity can be located on the top or bottom side of the card periphery and the endpoint can be at the top or bottom edge or top or bottom corner of the opening.

[0103] In some embodiments, for example, Fig.9A , Fig.19A and Fig. 30A , the discontinuity has an endpoint on the left edge of the opening at a position relatively closer to the lower left corner 125 than the upper left corner 123 and has an origin in the left side of the card periphery at a position relatively closer to the upper left corner 123 than the lower left corner 125. In other embodiments, for example, Fig. 8A , Fig. 10A , Fig.15A , Fig. 20A and Fig.21A , the endpoint position is relatively closer to the upper left corner 123 than the lower left corner 125, and the origin is located on the left side of the card periphery, relatively closer to the upper left corner 123 than the lower left corner 125. In other words, the interrupted paths of the above two types of embodiments are generally oblique and go downward from the origin to the endpoint, but the first group terminates on the left edge of the opening, closer to the bottom corner than the top corner.

[0104] As mentioned above and in e.g. Figure 1C , Figure 8C , Fig. 9C As shown in FIG. 1 and FIG. 2 , in the metal layer of the finished card, the transponder chip module 121 is arranged in the opening, and the metal layer serves as an amplified antenna for the transponder chip module. In the case of any metal layer such as that depicted and described herein, Fig.32 In the final card implementation of the layer 1100 depicted in FIG, the card may include at least one non-metallic layer 1200, 1300, such as but not limited to a plastic layer, a ceramic layer, a decorative layer comprising one of wood or leather, or a combination thereof, disposed on at least one surface of the metal layer 1100. Different types of layers or combinations thereof may be disposed on different surfaces of the card. As used herein, the term "disposed" means not only directly connected to the corresponding surface, but also indirectly connected (i.e., on top of one or more other layers directly connected to the surface).

[0105] In a preferred embodiment, the metal layer 1100 has step-shaped discontinuities 902, 1902, 3102, for example 9A to 9C , FIG. 19A to FIG. 19C and Fig.31A 31C , the card can have a front surface coated with a ceramic layer 1200 and a back surface with a plastic layer 1300 attached thereto, preferably by adhesive. As known to those skilled in the art, the attachment of the plastic layer with the adhesive can include using a carrier substrate (e.g., polyester) with adhesive (e.g., an ethylene copolymer adhesive, such as ethylene acrylic acid (EEA)) on both sides. As depicted in the cross-sectional view of FIG. 34 , in an embodiment having a ceramic layer 3400 including a ceramic coating over a metal layer 3410, the gap 3402 defined by the discontinuity can be at least partially filled with the ceramic coating so that the surface defects 3404 can still be seen from the top surface of the ceramic coating.

[0106] The discontinuities described herein may be optically visible from one or both surfaces of the card. In some embodiments, such as embodiments where the back surface is covered with an opaque plastic or translucent plastic with an opaque ink, the discontinuities may not be visible from the back surface. In embodiments with a front decorative layer such as wood, leather, or certain ceramics, the discontinuities may also be hidden from the front. However, in some ceramic-coated embodiments, the ceramic coating may only partially fill the gap caused by the discontinuity, so that the discontinuity is still visually perceptible, at least as an example. Fig.34 The surface defects 3404 shown are such that the defects can be in the form of at least a perceptible line (if not a perceptible gap). Therefore, it should be understood that in the figures showing the finished metal layer, the metal layer can be the top layer, or can be a layer that is covered by another layer but is still visually perceptible in some way.

[0107] In other discontinuity embodiments, the card may include multiple discontinuities, such as Fig.25A 28A. In all the embodiments shown, at least one of the plurality of interruptions (e.g., 2502, 2602, 2702, 2802) has a length equal to the shortest length from the opening to the periphery of the card, and at least two of the plurality of interruptions (e.g., 2502 and 2504, 2602 and 2604, etc.) are parallel to each other. In some embodiments, for example Fig.25AAs shown in , less than all of the multiple interruptions may extend from the periphery to the opening, meaning that while one or more interruptions (e.g., 2506) may extend only from the periphery of the card or the periphery of the opening, it does not extend to the periphery of the opening and the periphery of the card, and / or one or more interruptions (e.g., 2508, 2509, 2510) may not extend to the periphery of the card or the periphery of the opening. In a multiple interruption embodiment, the presence of multiple interruptions distributes the stress associated with bending over multiple locations, thereby minimizing stress whitening due to any one interruption. In the illustrated embodiment having multiple slits extending from the periphery of the card to the opening, the metal areas disposed between such slits are held in place by the overlying and underlying non-metallic layers of the card.

[0108] In a method for manufacturing a transaction card as described herein, the method includes the steps of: (a) providing a metal layer having a front surface and a back surface; (b) creating an opening in the metal layer, the opening being sized to accommodate a transponder chip module having the features described herein, (c) creating a discontinuity in the metal layer as described herein, and (d) positioning the transponder chip module in the opening. As described above, the step of creating the discontinuity may precede the step of creating the opening for the transponder chip module.

[0109] As described above, the method can include at least partially filling the gap defined by the discontinuity with a non-metallic material, such as a ceramic. The method can also include providing at least one non-metallic layer on the front surface or the back surface of the metal layer, for example by gluing the non-metallic layer to the metal layer or by spraying the ceramic layer on the metal layer. In some embodiments, the non-metallic layer includes a colored ceramic layer, wherein the method further includes creating one or more permanent marks on the ceramic layer using a laser having a color different from the color of the ceramic layer, as described later herein with respect to Fig.33More detailed description. In some embodiments, the permanent mark in the ceramic can be caused by a chemical change of the pigment in the ceramic composition, or the permanent mark can be produced by removing the overlying ceramic layer to expose the lower layer with different colors. If multiple ceramic layers are provided, the lower layer with different colors can include the lower ceramic layer. For example, it has been found that for certain types of cured ceramic spray coatings composed of ceramic particles, the ceramic particles include, for example, zirconium dioxide, aluminum disilicide, pigments and curable resin binders suspended in a carrier solution, where a white base ceramic layer with a white pigment can have better adhesion than a layer with a colored pigment, so the first white layer can be set below the second non-white ceramic layer. Alternatively, multiple ceramic layers can be used for aesthetic purposes. In other embodiments, the exposed lower layer with different colors can be a metal layer. In other embodiments, depending on the depth of the engraving, the composite metal core can promote the appearance of different colors. Engraving can be performed by any method, such as a chemical or mechanical method, and is not limited to laser marking. Finally, the grooves in the ceramic can be filled with another substance such as a metal. For example, a ceramic coated steel card may have laser engraved grooves in the ceramic coating that penetrate the metal, and then precious metals such as gold, silver, platinum, etc. or precious metals may be electroplated into the grooves as fillers.

[0110] The various configurations including ceramic layers as described herein are not limited to the card embodiments described herein having discontinuities in the metal layer. Although the ceramic layer may include one or more layers of a ceramic coating applied directly to the metal and cured, other methods of providing the ceramic layer may include adhering a freestanding monolithic ceramic layer to the metal layer or providing the ceramic coating on a substrate and then adhering the ceramic-coated substrate to the metal layer. In another method, the ceramic layer may be created by tape casting and adhered to the body.

[0111] According to the examples described herein, the cards with slot geometries as shown and claimed herein have functional advantages over the cards with straight slot geometries or other geometries of the prior art. Although all interrupted designs may have functional advantages over prior art designs, some designs have more functional advantages than other designs, and all or most may have relatively similar manufacturing costs, but some are considered more beautiful than others and are therefore favored purely for aesthetic reasons. Therefore, certain features of the interruptions in the metal layer disclosed herein can be selected for decorative design without being limited by practical functions. Therefore, the respective design elements can be changed and selected while maintaining functionality, so that various decorative configurations with substantially the same function or performance can be obtained. As a non-limiting example, the precise contours of the interruptions, such as the number of steps or twists in an embodiment with multiple interruptions, the height or stroke of the steps, the change in direction of the bend or non-bend, the curvature or change in direction, the precise location of the origin, end point and any inflection point, and the number of interruptions, can be changed to provide different decorative appearances while maintaining substantially the same function. The decorative design of the metal layer can be protected separately in one or more U.S. design patent applications.

[0112] The use of alternative slot designs can enable traditional metal or ceramic coated metal cards to overcome the potential weakness at the slot, allowing the card to maintain the traditional metal feel. Another option for reinforcing the card is to use a self-supporting layer on the back of the card, such as FR4 material (a thermosetting laminate made of epoxy resin and woven glass fiber) or polyimide. Printed layers such as for various markings, magnetic stripes, etc. can be assembled with the FR4 layer or printed directly on the FR4 layer. For example, in Fig.32 In one embodiment generally depicted in , a relatively thin (e.g., 0.009 inch thick) stainless steel substrate 1100 may be used, having an FR4 support layer 1300. In another embodiment, an 18 mil stainless steel layer may have: a 4 mil FR4 layer on its back side (attached to the stainless steel layer by a 2 mil adhesive layer); a 5 mil printed sheet on the back of the FR4 layer (attached via another 2 mil adhesive layer); and a 2 mil overlay layer including a magnetic strip laminated to the back side of the printed sheet layer. The printed sheet and magnetic strip overlay layers are layers that are susceptible to stress whitening, and the reinforcement layer helps prevent this phenomenon. Although the reinforced backing can fully overcome the weakness of the slit without using one of the other slit designs described herein, embodiments that combine both the FR4 (or other self-supporting) layer and one of the slit geometries described herein can also be provided. The preferred self-supporting layer has a stiffness of 80 MPa·m 3 To 40GPa·m 3 .

[0113] Therefore, now refer to Fig.32 , shows a cross-sectional view of an exemplary card embodiment 1000, which shows a metal layer 1100, which can be any metal layer described herein with or without slits, and has a stepped opening 1005 therein, the opening 1005 including an upper opening portion 1010 and a lower opening portion 1012. Fig.32 Also shown in the figure are front layer 1200 and back layer 1300. Layer 1200 has an opening 1205 that matches (i.e., coextensive with) the upper portion 1010 of the opening, so that the contact portion of the transponder module arranged in the opening in the metal card will be relatively flush with the upper surface of layer 1200. The thickness of the layer described in any of the drawings herein is not drawn to scale. In some embodiments, the front layer as described in Figure 32 can represent multiple layers, the back layer as described can represent multiple layers, the metal layer as described can represent multiple layers, or any combination thereof. Layers 1200 and 1300 are all optional. In one embodiment, layer 1200 can include 9 mil PVC or PVC / PEEK composite layers on the front of 10 mil metal layers and 10 mil PVC layers on the back of the metal layer. As known in the art, the front layer and the back layer can be adhered to the metal layer with a polyester substrate having an EEA adhesive on both sides, for example, with 2 mil adhesive layers. Some embodiments may have only a front layer or a back layer, but not both, and some metal card products may not have additional layers other than the coating to improve printability on the metal. For example, a card may include a printable metal, such as printable stainless steel, having a coating on at least the front side thereof that improves the acceptance of printed inks on the stainless steel surface. The coating may include, for example, a polyester-based coating that accepts UV-curable screen and inkjet inks or solvent or oxidative printing.

[0114] It should be understood that a manufacturer may provide the metal layer as an intermediate portion of a finished product, which may have additional layers added as part of subsequent processing. In one embodiment, as described herein, the front layer 1200 includes a ceramic layer (applied to the metal layer by any of the methods described herein), and the back layer includes a plastic layer. In another embodiment described herein, the back layer 1200 may be a self-supporting layer, such as a layer made of FR4.

[0115] like Fig.33As shown, in some embodiments, the ceramic layer 3300 on the metal layer 3302 may include at least two ceramic layers 3312 and 3314, each layer having a different color. Similarly, the metal layer 3302 may include at least two metal layers 3322, 3324, and the two metal layers may be different metals with different colors. Creating a design in the ceramic layer may include making a laser mark 3330 that changes color in the ceramic layer by permanently chemically changing the pigment in the ceramic layer or by removing a portion of the ceramic to form a groove. Such a groove may be a surface groove, such as a groove 3331 that does not penetrate the upper layer to expose the lower layer, or may be a groove that exposes the lower layer. The groove may be created by laser, mechanical or chemical methods known in the art. The grooves exposing the lower layer may include removing one ceramic layer 3312 to expose the groove 3332 of the other ceramic layer 3314, removing all ceramic layers 3312 and 3314 to expose the groove 3334 of the upper metal layer 3322, and removing all ceramic layers 3312, 3314 and the upper metal layer 3322 to expose the groove 3336 of the lower metal layer 3324. Another design technique may include creating a groove (such as any of the above groove embodiments) and then filling the groove in the ceramic with another material (e.g., electroplated metal 3338) that may be a metal different from the metal of one or both of the other metal layers. In order to fill the groove by electroplating, the initial groove is preferably a groove 3334 or 3336 in which the ceramic is removed down to the metal layer. Although presented in a single embodiment for illustration purposes only, each of the various grooves and marking techniques may be implemented alone or in any combination with other combinations described herein. And although described in conjunction with the various embodiments disclosed herein for enhancing the slit card design, the various techniques for creating decorations in ceramic cards are not limited to such embodiments.

[0116] Yet another embodiment of reinforcing a section of a card having a discontinuity comprises providing support tabs covering over and / or under the discontinuity, for example for FIG. 35A to FIG. 35E3500 shown in FIG. In one exemplary embodiment, for example, for an "all metal" card without a coextensive layer on the top or back surface of the card (optionally, except for a coating to facilitate printing), pockets 3510, 3512 around the opening 3520 of the module (not shown) are recessed on both sides of the card along the Z axis. The pockets 3510, 3512 on opposite sides of the card, both of which have an area less than the area of ​​the metal layer, are shown as having the same size as each other in the figure, but can be different sizes. Non-metallic inserts 3540, 3550 such as ceramic or plastic are placed in the pockets 3510, 3512. In a similar design of a "hybrid / single board card" (with one or more non-metallic layers on the back side of the metal layer, usually coextensive with the metal layer), the pockets and corresponding inserts can be arranged only on the front. The front insert 3540 has a hole 3545 to accommodate the module and expose the contact portion of the module on the top surface of the card. Use of an insert construction as disclosed herein can avoid the need to provide a stepped pocket in the metal layer for the transponder module, as the thickness of the pocket on either side can be chosen so that the "lip" (larger peripheral portion) of the module (not shown) rests on the shelf created by the card body, and the portion on the rear of the module protrudes through the hole 3520 in the card body and stops short of the inner surface of the rear insert 3550. The pattern can be applied to the insert by a laser or any method known in the art.

[0117] It should be understood that any of the methods disclosed herein for reinforcing the area around a discontinuity in a card (specific single slot geometry, multiple downwind geometry, reinforcing layers, or reinforcing pocket inserts) may be implemented alone or in combination with one another and, for example, using additional methods.

[0118] Any other method known in the art of creating a design or providing indicia on the card may also be provided, including providing a signature block, magnetic stripe, hologram, brand markings, personalized information, etc.

[0119] Example

[0120] When subjected to dynamic bending stress testing (referenced to ISO / IEC 10373-1:2006), the exemplary slot design embodiments described herein exhibit less ink cracking substrate stress whitening than other cards after bending in the short dimension (bending parallel to the long edge). Various embodiments were tested for up to 500 Flex test cycles at a rate of 30 cycles / minute per axis.

[0121]

[0122] Although the invention is shown and described herein with reference to particular embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the range of equivalents of the claims and without departing from the invention.

[0123] In addition, although the discontinuous geometry shown in this article has functional advantages over the geometry of the prior art, it should be understood that there are potentially infinitely many geometries, and those shown in this article are only a small part of the various available geometries consistent with the claims. Among the various available geometries, including multiple variations of specific geometries that can present appropriate performance and function, there may be certain preferred designs for purely aesthetic reasons. Therefore, unless otherwise specified, any specific design represented in this article by a specific geometry does not indicate that the specific design is functionally superior to alternative designs of similar or even different geometries. Similarly, patterns with multiple directional changes to some extent can have certain advantages, and the number of directional changes after a threshold number can be selected mainly for aesthetic reasons. Therefore, without prejudice to any number of design patent applications related to the specific design proposed herein, the description of this article is provided. The features represented by solid lines in the drawings of the invention patents herein are shown in dotted lines without damage to indicate that they are not included in the scope of the design patent claims. In particular, one or more features visible on the rear surface of the metal layer embodiments described herein may or may not be visible in the finished card due to one or more overlying layers and may therefore be shown in dashed lines when describing claimed design attributes to indicate that such features are not claimed. Similarly, details of the transponder module contacts are not claimed aspects of the invention and may be shown in dashed lines in any drawings describing claimed design attributes.

[0124] Although certain embodiments have been described with multiple directional changes, it should be understood that embodiments with fewer or more directional changes are possible. Similarly, although certain embodiments depict the locations of the discontinuity origin O and endpoint T in specific locations for a particular pattern, it should be understood that the location of each direction can vary along the periphery of the card or the periphery of the opening in the card.

[0125] Regarding the implementation methods including the above embodiments, the following technical solutions are also disclosed:

[0126] Solution 1. A transaction card having a card periphery defined by first and second parallel relatively short sides and first and second parallel relatively long sides, the card comprising:

[0127] a metal layer having a front surface and a back surface; and

[0128] an opening in the metal layer, the opening being sized to accommodate a transponder chip module, the opening having a first edge parallel to and relatively closest to a first short side of the card periphery and aligned with a first section of the card periphery, a second edge parallel to and relatively closest to a first long side of the periphery, and a third edge parallel to and relatively closest to the second long side of the periphery, the first edge being relatively closer to the short side of the periphery than the second edge is to the long side of the periphery, and the second edge being relatively closer to the first long side of the periphery than the third edge is to the second long side of the card periphery, the edges of the opening defining an angle, and

[0129] a discontinuity in the metal layer, the discontinuity comprising a gap in the metal layer extending from the front surface to the rear surface, the discontinuity defining a path starting at an origin at the periphery of the card and terminating at an endpoint in the opening, wherein one of the endpoint or the origin is relatively closer to a line defined by the first long side of the periphery than the other of the endpoint or the origin.

[0130] Option 2. The transaction card of Option 1, wherein a short side of the card periphery has an area aligned with the first edge of the opening, and the origin is located on the periphery outside the aligned area.

[0131] Option 3. The transaction card of Option 1, wherein the end point is located at a corner.

[0132] Embodiment 4: The transaction card of embodiment 1, wherein the end point is positioned relatively closer to an adjacent corner defined by a common edge than to one corner.

[0133] Embodiment 5. The transaction card of embodiment 1, wherein the path includes at least two changes in direction of 90 degrees or greater.

[0134] Embodiment 6. The transaction card of embodiment 5, wherein at least a portion of the discontinuous path defines a step-like geometry comprising more than two 90 degree changes in direction.

[0135] Embodiment 7. The transaction card of embodiment 5, wherein at least a portion of the discontinuous path defines a sawtooth geometry comprising more than two changes in direction greater than 90 degrees.

[0136] Option 8. A card according to Option 5, wherein the discontinuous path includes at least one direction change greater than 90 degrees and at least one direction change of 90 degrees.

[0137] Option 9. A card according to Option 8, wherein the discontinuous path includes micro-step-like geometries and macro-sawtooth-like geometries, including at least: a first plurality of more than two 90-degree direction changes, resulting in a first direction change greater than 90 degrees; and a second plurality of more than two 90-degree direction changes, resulting in a second direction change greater than 90 degrees.

[0138] Embodiment 10. The transaction card of embodiment 1, wherein the discontinuous path has at least one segment of a curved geometric shape.

[0139] Embodiment 11. The transaction card of embodiment 10, wherein the discontinuous path has one or more changes in direction greater than or equal to 90 degrees, wherein at least one change in direction has a curved geometry.

[0140] Option 12. A card according to Option 11, wherein the discontinuity has a sinusoidal shape, and the sinusoidal shape includes at least two changes in direction greater than 90 degrees.

[0141] Embodiment 13. The card of embodiment 1, wherein the discontinuity extends from a first short side of the periphery to a second edge of the opening.

[0142] Embodiment 14. The card of embodiment 1, wherein the discontinuity extends from the first or second long side of the periphery to the opening.

[0143] Option 15. A card according to Option 1, wherein the first edge and the second edge define a first corner of the opening, and the first edge and the third edge define a second corner of the opening, wherein the discontinuity extends from the first edge at a position relatively closer to the second corner than the first corner, and terminates at a short side of the periphery at a position relatively closer to the first corner than the second corner.

[0144] Option 16. A card according to Option 1, wherein the first edge and the second edge define a first corner of the opening, and the first edge and the third edge define a second corner of the opening, wherein the discontinuity extends from the opening at a position relatively closer to the first corner than the second corner, and terminates at a short side of the periphery at a position relatively closer to the first corner than the second corner.

[0145] Embodiment 17. The card according to Embodiment 1 further includes a transponder chip module disposed in the opening, wherein the metal layer includes an enhanced antenna or amplifier for the transponder chip module.

[0146] Embodiment 18. The card according to Embodiment 1 further includes a first non-metallic layer disposed on the first surface of the metal layer.

[0147] Option 19. A card according to Option 18, wherein the non-metallic layer includes a plastic layer.

[0148] Option 20. A card according to Option 18, wherein the non-metallic layer includes a ceramic layer.

[0149] Embodiment 21. A card according to Embodiment 20, wherein the ceramic layer includes a ceramic coating, and the gaps defined by the discontinuities are at least partially filled with the ceramic coating.

[0150] Embodiment 22. A card according to Embodiment 18, wherein the non-metallic layer includes a decorative layer comprising one of wood or leather.

[0151] Embodiment 23. The card according to Embodiment 18 further includes a second non-metallic layer disposed on the second surface of the metal layer.

[0152] Embodiment 24. A card according to Embodiment 23, wherein the first non-metallic layer comprises a ceramic layer, and the second non-metallic layer comprises a plastic layer.

[0153] Embodiment 25. A card according to embodiment 1, wherein the discontinuity is optically visible from one or both surfaces of the card.

[0154] Embodiment 26. A card according to embodiment 1, wherein the discontinuity is optically invisible from at least one surface of the card.

[0155] Option 27. A card according to Option 6, wherein the stepped geometry has a step height and a stroke, wherein the step height is greater than the stroke.

[0156] Option 28. A card according to Option 1, wherein the opening is a stepped opening having a first opening area defined in a first surface of the card and a second opening area defined in a second surface of the card, wherein the first opening area is larger than the second opening area.

[0157] Embodiment 29. A card according to Embodiment 18, wherein the non-metallic layer comprises a self-supporting layer.

[0158] Embodiment 30. The card according to embodiment 29, wherein the self-supporting layer comprises a polyimide or a glass fiber reinforced layer comprising an epoxy resin.

[0159] Embodiment 31. A card according to Embodiment 18, wherein the non-metallic layer comprises a ceramic insert disposed in a pocket, the periphery of the pocket being smaller than the periphery of the metallic layer.

[0160] Embodiment 32. The card of embodiment 31 comprises a first pocket and a first ceramic insert disposed in a front surface of the card, and a second pocket and a second ceramic insert disposed in a rear surface of the card.

[0161] Option 33. A card according to Option 31, comprising: a first pocket and a first ceramic insert disposed in the front surface of the card, and no pocket disposed in the rear surface of the card; and a rear non-metallic layer, the periphery of which is dimensionally the same as the periphery of the metal layer.

[0162] Embodiment 34. The transaction card of embodiment 10, wherein at least a portion of the discontinuous path defines a stepped geometry comprising more than two 90 degree changes in direction, wherein the curved geometry comprises a radius at each change in direction.

[0163] Solution 35. A transaction card comprising:

[0164] a metal layer having a front surface and a back surface; and

[0165] A plurality of interruptions in the metal layer, each interruption comprising a gap in the metal layer extending from the front surface to the bottom surface, at least one of the interruptions extending from a periphery of the metal layer and terminating in an opening sized to accommodate a transponder chip module, each of the plurality of interruptions having a certain length, wherein less than all of the plurality of interruptions extend from the periphery to the opening.

[0166] Embodiment 36. A method for manufacturing a transaction card, the card having a card periphery defined by first and second parallel relatively short sides and first and second parallel relatively long sides, the method comprising the steps of:

[0167] (a) providing a metal layer having a front surface and a back surface;

[0168] (b) creating an opening in the metal layer, the opening being sized to accommodate a transponder chip module, the opening having a first edge parallel to and relatively closest to a first short side of the card periphery and aligned with a first segment of the card periphery, a second edge parallel to and relatively closest to a first long side of the periphery, and a third edge parallel to and relatively closest to the second long side of the periphery, the first edge being relatively closer to the short side of the periphery than the second edge is to a long side of the periphery, and the second edge being relatively closer to the first long side of the periphery than the third edge is to the second long side of the card periphery, the edges of the opening defining angles, and

[0169] (c) creating a discontinuity in the metal layer, the discontinuity comprising a gap in the metal layer extending from the front surface to the back surface, the discontinuity defining a path beginning at an origin at the periphery of the card and terminating at an endpoint in the opening, wherein one of the endpoint or the origin is positioned relatively closer to a long side of the periphery than the other;

[0170] (d) Placing the transponder chip module in the opening.

[0171] Solution 37. A transaction card comprising:

[0172] a metal layer having a front surface, a rear surface, a periphery, and an opening sized to accommodate a transponder chip module;

[0173] at least one discontinuity in the metal layer extending from the front surface to the back surface, the at least one discontinuity comprising a gap having a width and extending from an origin on a periphery of the metal layer and terminating at an end point in the opening; and

[0174] A self-supporting non-metallic layer is disposed on at least one surface of the card.

[0175] Solution 38. A transaction card comprising:

[0176] a metal layer having a front surface, a rear surface, a periphery, and an opening sized to accommodate a transponder chip module;

[0177] at least one discontinuity in the metal layer extending from the front surface to the back surface, the at least one discontinuity comprising a gap having a width and extending from an origin on a periphery of the metal layer and terminating at an end point in the opening; and

[0178] One or more ceramic reinforcement tabs surround the opening and are disposed on one or both surfaces of the card.

[0179] Solution 39. A transaction card comprising:

[0180] a metal layer having a front surface, a back surface and an opening sized to accommodate the transponder chip module, the opening having a first edge parallel to and relatively closest to a first short side of the card periphery and aligned with a first portion of the card periphery, a second edge parallel to and relatively closest to a first long side of the periphery, and a third edge parallel to and relatively closest to the second long side of the periphery, the first edge being relatively closer to the short side of the periphery than the second edge is to the long side of the periphery, and the second edge being relatively closer to the first long side of the periphery than the third edge is to the second long side of the card periphery, the edges of the opening defining an angle;

[0181] at least one discontinuity in the metal layer extending from the front surface to the back surface, the at least one discontinuity comprising a gap having a width and extending from an origin on a periphery of the metal layer and terminating at an end point in the opening;

[0182] The card has greater resistance to damage caused by bending of the card than a card having a discontinuity having the same gap width and whose endpoints and origin are located at the same distance from a line defined by the first long side of the periphery without one or more strengthening features, wherein the greater resistance is provided by a strengthening feature selected from the group consisting of:

[0183] (a) a single discontinuity, wherein one of the endpoint or the origin is relatively closer to a line defined by the first long side of the periphery than the other;

[0184] (b) a plurality of interruptions, each interruption having a length, wherein less than all of the interruptions in the plurality of interruptions extend from the card periphery to the opening;

[0185] (c) a self-supporting non-metallic layer disposed on at least one surface of the card;

[0186] (d) one or more ceramic reinforcement tabs surrounding the opening and disposed on one or both surfaces of the card; or

[0187] (e) any combination of the above.

Claims

1. A transaction card having a card periphery defined by a plurality of sides, the plurality of sides comprising first and second parallel short sides and first and second parallel long sides, the short sides being relatively shorter than the long sides, the card comprising: a plurality of metal layers, each metal layer having a front surface and a back surface; as well as an opening in at least one of the plurality of metal layers, the opening being sized to accommodate a transponder chip module, the opening having a first edge parallel to and relatively closest to a first short side of the card periphery and aligned with a first section of the card periphery, a second edge parallel to and relatively closest to a first long side of the card periphery, and a third edge parallel to and relatively closest to the second long side of the card periphery, the first edge being relatively closer to the short side of the card periphery than the second edge is to a long side of the card periphery, and the second edge being relatively closer to the first long side of the card periphery than the third edge is to the second long side of the card periphery, the edges of the opening defining an angle; and a discontinuity in at least a first metal layer of the plurality of metal layers, the discontinuity comprising a gap in the metal layer extending from the front surface to the back surface, the discontinuity defining a path starting at an origin at the card periphery and terminating at an endpoint in the opening, wherein one of the endpoint or the origin is relatively closer to a line defined by a first long side of the card periphery than the other of the endpoint or the origin, and the path has a length greater than a shortest distance from the endpoint to a side of the card periphery containing the origin, wherein the short side of the card periphery has an area aligned with a first edge of the opening, and the origin is positioned on the card periphery outside of the alignment area, Wherein at least a second metal layer of the plurality of metal layers also includes a discontinuity, wherein at least a portion of the discontinuity in the first metal layer is aligned with a region of the second metal layer that does not include the discontinuity in the second metal layer.

2. The transaction card according to claim 1, wherein: At least one of the plurality of metal layers other than the first metal layer also includes a discontinuity.

3. The transaction card of claim 1, wherein: The path includes at least two changes of direction of 90 degrees or greater.

4. The transaction card according to claim 3, wherein: At least a portion of the interrupted path defines a step-like geometry that includes more than two 90 degree changes in direction.

5. The transaction card of claim 1, wherein: The interrupted path has at least one section with a curved geometry.

6. The transaction card of claim 5, wherein: The discontinuous path has one or more changes in direction greater than or equal to 90 degrees, wherein at least one change in direction has a curved geometry.

7. The transaction card of claim 1, wherein: The discontinuity extends from a first short side of the card periphery to a second edge of the opening.

8. The transaction card of claim 1, wherein: The discontinuity extends from the first long side or the second long side of the card periphery to the opening.

9. The transaction card of claim 1, further comprising a transponder chip module disposed in the opening, wherein: One or more of the plurality of metal layers includes a booster antenna or amplifier for the transponder chip module.

10. The transaction card of claim 1, further comprising a first non-metallic layer disposed on a surface of the first metal layer.

11. The transaction card of claim 10, wherein: The non-metallic layer includes a plastic layer.

12. The transaction card of claim 10, wherein: The non-metallic layer includes a ceramic layer.

13. The transaction card of claim 12, wherein: The ceramic layer includes a ceramic coating, and the gaps defined by the discontinuities are at least partially filled with the ceramic coating.

14. The transaction card of claim 10, further comprising a second non-metallic layer disposed on a surface of the second metal layer.

15. The transaction card of claim 14, wherein: The first non-metallic layer comprises a ceramic layer, and the second non-metallic layer comprises a plastic layer.

16. The transaction card of claim 10, wherein: The first non-metallic layer comprises a self-supporting layer.

17. The transaction card of claim 16, wherein: The self-supporting layer comprises a polyimide or a glass fiber reinforced layer comprising an epoxy resin.

18. The transaction card of claim 1, wherein: The first metal layer defines a first area and includes a pocket defining a second area smaller than the first area, and also includes a non-metallic insert disposed in the pocket.

19. The transaction card of claim 1, wherein: At least one discontinuity in the first metal layer comprises a recess that visually exposes the second metal layer from an exterior surface of the transaction card.

20. The transaction card of claim 19, wherein: At least a portion of the second metal layer is processed to have a different color than the first metal layer visibly from the outer surface of the card, the second metal layer includes a different metal from the first metal layer, or at least a portion of the second metal layer is processed to have a different color than the first metal layer visibly from the outer surface of the card and includes a different metal from the first metal layer.

21. The transaction card of claim 1, wherein: The end point is located on the first edge at a point unequally spaced from the second edge and the third edge or is located on the second edge or the third edge at a point unequally spaced from the first edge and a fourth edge opposite the first edge.

22. The transaction card of claim 1, further comprising a non-metallic material disposed in gaps defined by the discontinuities.

23. The transaction card of claim 22, further comprising a non-metallic layer disposed on at least one surface of the first metal layer, wherein the non-metallic layer at least partially fills a gap defined by the discontinuity.

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