Metal, ceramic, or ceramic-coated transaction cards with windows or window patterns and optional backlighting

Abstract

A transaction card (1900) includes at least one metal layer (1910) having one or more apertures (1920, 1930). A light guide (1933) is disposed below the metal layer. The light guide has a light output and a light input. The light output is positioned to transmit light through the at least one or more apertures in the metal layer. At least one LED (1935) is positioned to transmit light into the light guide light input.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. patent application Ser. No. 16 / 751,285, filed on Jan. 24, 2020, entitled “METAL, CERAMIC, OR CERAMIC-COATED TRANSACTION CARD WITH WINDOW OR WINDOW PATTERN AND OPTIONAL BACKLIGHTING,” the contents of which are incorporated herein by reference in their entirety for all purposes. Background Art

[0003] Transaction cards can have any number of features to differentiate one product from another. Consumers have expressed a desire for metal cards due to their durability and overall luxury feel compared to plastic. Ceramic cards offer similar durability with a unique and desirable overall luxury feel.

[0004] U.S. Patents Nos. 5,412,199, 5,434,405, and 5,608,203 disclose credit cards having a plastic base material with a transparent region forming a magnifying lens, such as a Fresnel lens, which allows the card to be used as a magnifying glass, for example, to read fine print on transaction receipts. U.S. Patent No. 6,902,116 discloses a transaction card having a transparent window with collimating properties for focusing LED light.

[0005] U.S. Patent No. 7,997,503 discloses a card having a plastic substrate with a transparent window having a set of fixed elongated segments printed thereon, the transparent window, when superimposed on a display of a dynamic visual code combined with the set of elongated segments, presenting a visual code to a viewer looking through the window. Thus, such a card has printed information on the window, and the printed information on the window is functional in nature, as the pattern must be aligned with the elongated segments combined with the visual code.

[0006] Providing a card with a primarily metal, ceramic, or ceramic-coated body (such as metal) allows the card to have a certain look and feel (e.g., weight) that plastic cards lack, and providing a transparent window in such a card provides a desirable distinction from other card products. Metal and / or ceramic cards are generally more expensive to produce and, therefore, may be offered as luxury cards targeted at cardholders who have a net worth above a certain threshold, are members of a select group of high-value customers for the card issuer, and / or are willing to pay a substantial annual fee. Carriers of such luxury cards may not wish to allow for any need for a magnifying lens and, therefore, may not desire a magnifying or collimating transparent window. Carriers of such cards may prefer that the central portion of the transparent window be free of printing that obscures the view through the card, or that the window be decorated with decorative, non-functional patterns, rather than elongated segments of functional patterns (such as those described in U.S. Patent No. 7,997,503), which tend to be aesthetically unpleasing. Embedding a transparent window in a metal and / or ceramic frame may present manufacturing and structural challenges and opportunities that differ from the types of cards described in the aforementioned references.

[0007] Card users and manufacturers often desire to incorporate designs that are visually and / or tactilely perceptible from at least one surface of the card. For example, U.S. Patent Application Serial No. 20060086802 discloses a gemstone-laden card in which the gemstone is embedded within a plastic card. Card issuers and cardholders may be interested in creating a design that provides an appearance similar to a gemstone pattern without the labor-intensive steps and expense of embedding numerous individual gemstones within the card. Summary of the Invention

[0008] One aspect of the present invention includes a transaction card having opposing machined surfaces and a perimeter, the transaction card comprising: a metal layer having opposing surfaces and at least two openings, each opening extending through one or both of the opposing machined surfaces; a transponder module disposed in one of the at least two openings in the metal layer; and an LED module disposed in the other of the at least two openings in the metal layer and having a planar illumination area visible from the machined surface of the transaction card. The transponder module comprises a component of a transaction circuit configured to wirelessly communicate with a card reader. The card reader is configured to emit radio frequency (RF) waves having energy. The transaction circuit is configured to receive an input RF signal from the card reader, respond by outputting an RF signal, and power the transaction circuit by harvesting energy from the RF waves. The LED module comprises: one or more LEDs configured to emit light; and a light guide for distributing light emitted by the one or more LEDs over the illumination area. In some embodiments, the LED module comprises a component of a lighting circuit configured to harvest energy from the RF waves to power the one or more LEDs. The illumination circuit may be configured to illuminate independently of the status of the payment transaction performed by the transaction circuit. In other embodiments, the illumination circuit and the transaction circuit comprise components in a unified circuit, in which the illumination circuit is configured to illuminate in a manner that indicates the status of the payment transaction performed by the transaction circuit.

[0009] The metal layer may have at least one discontinuity extending from the periphery of the card to at least one of the at least two openings in the metal layer. The at least one discontinuity may be connected to the at least two openings and extend between the at least two openings. The metal layer may have a first discontinuity extending from the periphery of the card to the opening containing the transponder module and a second discontinuity extending from the periphery of the card to the opening containing the LED module. The card may also include at least one non-metallic layer disposed on each opposing surface of the metal layer. The printed pattern may cover the illuminated area of ​​the LED module. The LED module may be located in the metal layer at a position that improves the RF performance of the transponder module relative to a card without the LED module.

[0010] A lighting circuit can be configured to have variable lighting characteristics that depend on characteristics of the harvested energy. For example, the lighting circuit can include at least one LED with variable intensity, wherein the LED is configured to illuminate at a first, relatively low intensity in response to harvested energy within a first, relatively low range, and at a second, relatively high intensity in response to harvested energy within a second, relatively high range. A lighting circuit having at least two LEDs can be configured to illuminate one of the at least two LEDs in response to harvested energy within the first, relatively low range, and to illuminate the other of the at least two LEDs in response to harvested energy within the second, relatively high range. The first and second ranges can overlap, such that the lighting circuit is configured to illuminate both of the at least two LEDs when the harvested energy is within the overlapping range. The at least two LEDs can each be configured to emit light of the same wavelength, or at least one of the at least two LEDs can be configured to emit light of a different wavelength than the other of the at least two LEDs. For example, one of the at least two LEDs can be configured to generate light with a wavelength in the green visible spectrum, and the other of the at least two LEDs can be configured to generate light with a wavelength in the red visible spectrum. In such an embodiment, the lighting circuit can be configured to illuminate the red LED in response to harvested energy within a first, relatively low range, illuminate the green LED in response to harvested energy within a second, relatively high range, and illuminate both the red and green LEDs when the harvested energy is in response to harvested energy within a third intermediate range between the first, relatively low range and the second, relatively high range. One or both of the red and green LEDs can be configured to illuminate at variable intensity.

[0011] Yet another embodiment may include a transaction card comprising a metal layer having a visual appearance, a thickness, a front surface, a back surface, and one or more windows or slots extending through at least the front surface. A transponder module and an insert may be disposed in the one or more windows or slots, respectively. The front surface of the insert, visible through the windows, has a different visual appearance than the metal layer. The one or more non-functional features visible from the front surface of the card contrast with the visual appearance of the front-facing surface of the insert disposed below the non-functional features. The insert is one of: (a) non-transparent and non-translucent; or (b) transparent or translucent and configured to transmit backlight through the back surface of the card to the non-functional features. The insert is positioned in the metal layer to improve the RF performance of the transponder module relative to a card without the insert. In some embodiments, the non-functional features include printed features. In some embodiments, the insert is non-transparent and non-translucent, but has an illuminable front-facing surface. The insert may include an illuminable LED display, such as one powered by energy harvested from RF waves. In an embodiment in which the metal layer has at least two openings, the transponder module may be arranged in one of the at least two openings, and the insert may be arranged in the other of the at least two openings.

[0012] The transponder module may include transaction circuitry configured to inductively couple the transponder module to a card reader using RFID technology. The illuminable LED display may be configured to illuminate as an indicator of the card's operability, or to illuminate independently of the status of a payment transaction being executed by the transaction circuitry. In embodiments where the insert is translucent or transparent and the window extends from the front surface of the metal layer to the back surface of the metal layer, non-collimated light may pass through the insert to provide contrast with one or more non-functional features visible from the front surface of the card. The non-functional features may include at least one of printed, engraved, etched, or cut features. The window or slot may include a plurality of openings in the front surface of the metal layer, the plurality of openings defining one or more non-functional features disposed within a first region. At least one opening in the back surface of the body may be aligned with the first region, and the insert may be disposed in the at least one opening in the back surface of the body, positioned such that the front-facing surface of the insert is recessed relative to the front surface of the metal layer, such that the front-facing surface of the insert is visible through the plurality of openings in the front surface of the metal layer. A backing layer may be laminated to the back surface of the body. A portion of the insert or the opening containing the insert may be partially obscured by printed or decorative content.A first discontinuity extends from the periphery of the card to the opening containing the transponder module and a second discontinuity extends from the periphery of the card to the opening containing the LED module.

[0013] The illuminable LED display may include: one or more LEDs configured to emit light; and a light guide for distributing the light emitted by the one or more LEDs over an illuminated area of ​​a front-facing surface of the insert; or an OLED module. The illuminable LED display may have variable illumination characteristics depending on the amount of energy collected, including one or more LEDs having variable intensity and / or configured to emit the same or different wavelengths and / or configured to illuminate in different combinations (as described in more detail herein). BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1A Depicted is the front of an exemplary transaction card having a transparent window according to an aspect of the present invention.

[0015] Figure 1B depiction Figure 1A Exploded cross-section of the card.

[0016] Figure 1C Depicts Figure 1A The back of the card.

[0017] Figure 2 Describes the multiple cuts you can make Figure 1A An exemplary sheet of card.

[0018] Figure 3 An exemplary card is depicted having a window with electronics disposed thereon.

[0019] Figure 4 An exemplary card having a multi-layer window with embedded electronics is shown.

[0020] Figure 5 An exemplary card having a window with embedded electronics is depicted.

[0021] Figure 6 An exemplary card having a window with embedded electronics and an embedded antenna is depicted.

[0022] Figure 7 A perspective view depicting the front side of an exemplary card embodiment having multiple window openings.

[0023] Figure 8 Depicts Figure 7 A perspective view of the back of an exemplary card and insert.

[0024] Figure 9 Depicts Figure 8 A perspective close-up view of the front face of the body and insert and the outer periphery of an exemplary card.

[0025] Figure 10A Depicts a plan view of an exemplary card having multiple window openings cut into a pattern.

[0026] Figure 10B Depicted is a plan view of an exemplary card having a plurality of narrow slit window openings cut into a pattern that collectively form alphanumeric characters.

[0027] Figure 10C Depicted is a plan view of an exemplary card having a plurality of narrow slit window openings, each cut into a pattern of alphanumeric characters.

[0028] Figure 11 Depicted is a cross-sectional view of an exemplary card having multiple window openings on the front face.

[0029] Figure 12 Depicts Figures 7 to 9 A cross-sectional view of an exemplary card.

[0030] Figure 13 Depicted is a cross-sectional view of the window area of ​​an exemplary card embodiment in which a plurality of window openings are filled or partially filled with protruding insert material.

[0031] Figure 14 Depicted are cross-sectional views of the window areas of exemplary card embodiments in which a plurality of window openings are filled or partially filled with a translucent or transparent material different from the insert material.

[0032] Figure 15 Depicted is a cross-sectional view of the window area of ​​an exemplary card embodiment in which a plurality of window openings are filled or partially filled with a translucent or transparent material protruding from a layer or coating disposed on the front surface.

[0033] Figure 16 Depicted is a cross-sectional view of the window area of ​​an exemplary card embodiment in which a plurality of window openings are filled or partially filled with a translucent or transparent material protruding from a layer or coating disposed beneath the front surface.

[0034] Figure 17 Depicted is a cross-sectional view of the window area of ​​an exemplary card embodiment in which the plurality of window openings are filled with or have a translucent or transparent material from a layer or coating disposed on top of the front and back surfaces.

[0035] Figure 18 Depicted is a cross-sectional view of the window area of ​​an exemplary card embodiment in which a light guide transmits light through a plurality of window openings.

[0036] Figure 19A Depicted is a plan view of an exemplary transaction card including a printed design backlit by an LED module.

[0037] Figure 19B Depicts Figure 19A Cross-section of the card.

[0038] Figure 19C An exemplary LED module is depicted that includes a light guide with side-firing LEDs. DETAILED DESCRIPTION

[0039] Referring now to the accompanying drawings, Figures 1A to 1C An exemplary transaction card 100 is depicted that includes a relatively thick body 102, a window insert 112, and a backing layer 120. The body 102 has a thickness (T), a front face 104, a back face 106, and an aperture 108 extending from the front face to the back face. Figure 1A and Figure 1C As depicted, the aperture 108 has a circular edge, but it will be appreciated that the edge of the aperture may take any geometric shape (oval, triangle, square, rectangle, or any regular or irregular polygonal shape having three or more sides), or it may have an edge that includes a combination of curved and / or linear portions that do not fit into any of the aforementioned geometric categories. It will also be appreciated that the transparent or translucent window may be of any size characterized by its total area, so long as its total area is less than the area of ​​the body 102, and is preferably entirely contained within the area of ​​the card (i.e., the perimeter of the window is entirely radially inward of the perimeter of the body).

[0040] A non-magnifying window insert 112 having a front face 114, a back face 116, the same thickness (T) as the body 102, and edges that match the edges of the hole 108 is positioned in the hole. The window can be non-magnifying and non-aligned. By "matching" edges it is meant that the window insert has edges that are the same as the edges of the hole, but is of a diameter (or its equivalent) sufficiently smaller to be inserted into the hole without being forced to fit the hole, leaving no gap, or a gap that is minimal and barely perceptible to the human eye, at the interface between the inner edge of the hole and the outer edge of the insert. Similarly, by "same" thickness it is meant that the window insert and the metal body have the same thickness within acceptable tolerances relative to the desired level of accuracy, recognizing that such tolerances may include differences in thickness that are perceptible to the human touch or to account for differences in thickness due to the thickness of a printed layer on the body.

[0041] In some embodiments, the window insert has no functional printed content on (or embedded in) the front or back sides thereof. "No functional printed content" means that, in some embodiments, the insert has no content printed thereon at all (not shown), or in other embodiments, any content printed on the insert (e.g., the ship graphic 118 depicted in FIG. 1 ) is purely decorative in nature and, for example, is not used in conjunction with an authentication or verification scheme achieved by placing the window over the corresponding graphic. Instead of or in addition to printing, the graphics or other content provided in the window may also be engraved, etched, or otherwise cut into the window. The engraved, etched, or otherwise cut content in the window may also be non-functional, including aesthetic content having 3D relief properties, for example, to provide an embossed jewelry-like appearance. In other embodiments, as further described herein, the window may include electronics (e.g., LEDs) mounted thereon or therein, in which case, preferably, "invisible" or minimally visible (not visible to the naked human eye in ambient lighting without close inspection) traces may be printed or otherwise provided on or in the window. Such traces can connect the LED to electrical traces in the body, which can be connected to a hidden power source in the body or can be connected to a source and / or receiver of electrical signals. In some embodiments, the LED can include a backlight LED. The window can include a light guide that transmits light from a light source (e.g., an LED) located at the input surface of the light guide to the output surface of the light guide. However, it should be understood that all electrical signals have some inherent electrical power, as the term "electricity" as used herein refers to electrical power used to power electronic features, while the term "electrical signal" as used herein refers to a signal that is not used to provide power but rather to transmit information. Therefore, the electrical pulses traveling to the electronic features and from the electronic features to any connected components can include electrical power, electrical signals, or a combination thereof.

[0042] By "non-magnifying" is meant that the window insert is not functional and does not act like a magnifying lens (i.e., an object at a given distance viewed through the window insert appears the same size as if it were not viewed through the window). By non-collimating is meant that the window does not focus radiation of any wavelength (not limited to visible light) that passes through the window toward a focal point. The window can be light diverging. The window insert is non-metallic and preferably comprises polished polycarbonate, but can comprise glass or any transparent plastic or resin known in the art. In some embodiments, the window insert can have a predominantly transparent or translucent area with one or more different materials embedded within it, such as metal, ceramic, wood, crystal, natural or synthetic gemstones, mother-of-pearl, leather, etc. Although referred to herein as "transparent," the window may cause sufficient light scattering and diffusion such that objects viewed through the window are not visible with optimal clarity. The window alone is more transparent than the combination of the window and backing layer (and any layer on top of the window). The material of the window insert can be selected to be anywhere between translucent (where objects viewed through the window cannot be clearly seen at all) and transparent (where objects viewed through the window can be clearly seen). At a minimum, the window should be translucent for the spectrum of light visible to the typical human eye (i.e., wavelengths from approximately 390 nm to 700 nm and frequencies in the range of approximately 430 THz to 770 THz). In a preferred embodiment, the window is not tinted. Thus, for example, when stacked in a cardholder's wallet, the window can allow the user to clearly see the card immediately beneath it.

[0043] In some embodiments, it may be desirable for the window to be conductive or have conductive features. For example, in some embodiments, the window may comprise glass or another non-conductive material (e.g., a plastic resin) coated with a conductive coating (e.g., an indium tin oxide coating) or conductive ink. In other embodiments, the window may comprise, in whole or in part, a conductive plastic (i.e., polycarbonate or another plastic material formed from a conductive plastic resin).

[0044] In some embodiments, as Figures 3 to 6As depicted in FIG, the card 300, 400, 500, 600 can have an electronic device 310, 410, 510, 610, such as an integrated circuit, an LED inlay, a switch, or any other electronic feature known in the art, incorporated into the window 320, 420, 520, 620 using "invisible" traces 330, 430, 530, 630 comprising ITO or other printed conductive ink or adhesive that can connect the electronic device to an electrical connector 340, 440, 540 at the interface between the window and the body 350, 450, 550 at the edge of the aperture. In some embodiments, the electrical connector 340, 440, 550 can then be connected to a power source 360, 460, 560, such as a battery, or an antenna for harvesting RF power. Thus, for example, an LED display such as for displaying a dynamic code or for emitting light to provide an indication of card operability (e.g., illuminated when information is actively read from the card) can be bonded to or embedded in the window and connected to connection points at the periphery of the window using ITO or other printed traces. All or only the portion of the electronic device that is required to be conductive can be bonded to the window using a conductive adhesive and / or all or only the portion of the electronic device that is intended to be non-conductive can be bonded to the window using a non-conductive adhesive. The use of printed conductive traces using a transparent, translucent, or minimally visible thin conductive material allows the electronics to be incorporated into the window without unsightly, easily visible wiring or copper traces.

[0045] Features with electric drive in the window (such as Figures 3 to 5In the depicted embodiment (where power is supplied to the feature from a power source embedded in the body), power can be connected to the feature inductively or through a physical trace, where the physical trace in the body is connected to the physical trace in the window across a conductive interface that bridges any gap between the window and the body. The conductive interface 335, 435, 535 can include, for example, solder, wire bond, conductive ink, or a conductive adhesive (such as a conductive adhesive patch or ACF tape). The conductive interface 335, 435, 535 and any traces 340, 440, 540 embedded in the metal body 350, 450, 550 are insulated from the metal body by any insulator and method for providing an insulator known in the art. For example, as known in the art, the traces 340, 440, 540 can include copper traces on a flexible non-conductive substrate provided in a groove in the body. The conductive interface can simply include connection terminals connecting the traces (e.g., 330 and 340), or can be slightly larger than the connection traces to facilitate alignment when the window is inserted into the hole. It may be particularly effective to apply a conductive interface 335, 435, 535 in the form of a solder bump after the window is inserted, which is applied to bridge the gap between the traces 330, 430, 530 in the window and the traces 340, 440, 540 in the card. To facilitate alignment of the electrical connections, the hole and the corresponding insert may be non-circular or may be keyed, for example having a protrusion in the window that mates with a recess in the hole (or vice versa), so that the insert fits the hole only in a single or a limited number of easily distinguishable orientations.

[0046] exist Figure 6 In the depicted embodiment, the electronic feature 610 disposed in the window 620 can be powered entirely by inductively obtaining RF from the card reader, wherein the antenna 630 is also disposed in the card and connected to the electronic feature without requiring connection to a power source embedded in the body 650. Thus, for example, where the electronic feature 610 is a lighting feature that is activated when the card is read, the antenna 630 obtains sufficient power to power that lighting and does not require connection to any other features embedded in the card. In other constructions, the electronic feature 610 and / or antenna 630 can be disposed on the surface of the card rather than embedded in the card. In other embodiments, the electronic feature 610 and / or antenna 630 can be powered inductively (or by a power source similar to Figures 3 to 5 The connection of any of those connections shown in FIG. 1 is physically connected to a feature embedded in the body (e.g., a power source), or, for example, in an embodiment where the electronic feature is a dual-interface chip, to contacts (e.g., contacts 160 depicted in FIG. 1 ) for reading by a contact-based reader.

[0047] Window pattern implementation

[0048] In another aspect of the present invention, the transaction card may be Figures 7 to 17The depicted card includes a plurality of openings in the front face. Specifically, as Figure 10A As shown, the plurality of window openings 1010 in the card body 1000 form a spherical geometric pattern. Figure 10B As shown, the plurality of window openings 1022, 1024, 1032 in the card 1020 collectively form a stylized Q-shaped alphanumeric character associated with a particular card brand. Figure 10C As shown, each of the plurality of window openings 1052 includes alphanumeric characters that are arranged together such that the window openings spell out a word associated with a particular card brand. Figures 7 to 9 The opening is generally depicted as a collection of different ellipses in Figures 11 to 15 In cross-section, they do not have a recognizable geometric shape. The shape, size and number of the pattern and the openings that form the pattern are not limited in any way. The openings can form a recognizable pattern or an abstract pattern. The openings are preferably merely aesthetic in nature and do not serve any function other than to produce a suitable pattern or design, which may be selected by the user or may be selected to be difficult to copy. Therefore, although the pattern or design can enhance the security of the card in a passive way - in that the pattern or design provides a mark of authenticity that is difficult to copy by its own existence, preferred patterns or designs are referred to herein as "non-functional" because they do not have an active or interactive function.

[0049] like Figures 7 to 9 , the card body 700 has a plurality of window openings 702, 704, and 706 extending through the front face of the card body. Although referred to herein and in the appended claims as the "front" side, the term "front" as used herein in conjunction with this embodiment and other embodiments refers to the side of the card on which the window openings are located, which may be the side conventionally referred to as the "front" side or the "back" side of a functional card having a magnetic stripe, contacts, and other markings that are generally understood to distinguish the "front" from the "back" of a card. Each opening has a different perimeter visible from the front side of the card, but all of the window openings are positioned as indicated by the front edge of the card. Figure 8 The insert 800 is configured to be disposed in the pocket 804. Figure 8 、 Figure 9 and Figure 12 As depicted, the card body 700 has a recessed flange 802 on the back side surrounding a single opening 804, wherein the insert 800 includes a stepped perimeter including an outermost region 902 having a geometry configured to mate with the recessed flange and an innermost region 904 configured to fit within the single opening.

[0050] exist Figure 11In another embodiment depicted, the body can include at least two layers, including a first layer 1100 defining a front side 1150 of the body and a second layer 1102 defining a back side 1152 of the body. A plurality of openings 1110a, 1110b, 1110c penetrate the entire thickness of layer 1100, while a single opening 1120 penetrates the entire thickness of layer 1102. Insert 1104 is configured to fit within opening 1120, which defines a slot when layers 1100, 1102 are combined together. Although a recessed lip in layer 1102 and a corresponding outer peripheral area on insert 1104 are not shown, such features may also be present in this embodiment. Although in Figure 11 1104. The two layers 1100 and 1102 are depicted as having the same thickness, but the two layers 1100 and 1102 can have different thicknesses, and either can be larger than the other. The layers can be bonded together with an adhesive. Additional layers can also be present, including a transparent or translucent adhesive layer between layers 1100 and 1102, which fills the plurality of openings 1110a to 1110c during the lamination step. A backing layer 1106 can be laminated or otherwise bonded to the back of layer 1102 to hold the insert 1104 in place.

[0051] like Figure 11 As shown, the insert may include only member 1104. In some embodiments, member 1104 and backing layer 1106 (and any intermediate or upper layers) may be transparent or translucent, allowing light to be visible through openings 1110a to 1110c. However, in a preferred embodiment, insert 1104 includes a non-transparent member selected for aesthetic effect. For example, insert 1104 may include plastic, metal (e.g., having visual properties different from any visible metal in the body), ceramic (e.g., having visual properties different from any ceramic or ceramic coating comprising the body), wood, crystal, mother-of-pearl, stone (including artificial or natural gemstones), natural or synthetic bone products, and natural or synthetic leather. Any of the foregoing may have printing thereon (e.g., a printed plastic insert with graphics that provide different colors visible through different openings). Typically, the non-transparent member is opaque, but in other embodiments, the non-transparent member may have some translucency. Member 1106 may have printing on one or both sides, including, in some embodiments, printing that is visible from one surface of the card that is different from the printing that is visible from the opposite surface of the card.

[0052] Typically, member 1104 is passive and static, but it can be dynamic, such as a photoluminescent member (e.g., glowing in the dark or fluorescing when illuminated by light of a specific wavelength). Member 1104 can also be a light source such as an LED, more specifically a backlight LED, connected to a power source (not shown) in the same manner as described herein for other elements connected to a power source. In another embodiment, member 1104 can be a light guide that receives light input from a light source such as an LED or backlight LED (not shown) at an input surface of the light guide and transmits the light to an output surface. The light can cooperate with the window to produce a pattern that illuminates to indicate, for example, the reading of a payment module, but is not limited to any particular purpose.

[0053] In yet another embodiment, member 1104 may include an OLED (organic light emitting diode). The use of OLED components in transaction cards is generally described, for example, in U.S. Patent No. 9,665,818, entitled “ORGANIC LIGHT EMITTING DIODE (“OLED”) UNIVERSAL PLASTIC,” and PCT Publication No. WO2013131153A1, entitled “FLEXIBLE OLED CARD,” both of which are incorporated herein by reference. While the referenced disclosures describe the use of OLED technology in conjunction with flexible plastic cards, it should be understood that the general technology for providing OLED displays is applicable to incorporating OLED displays into relatively inflexible card constructions or flexible card constructions. However, the flexibility of an OLED display may be particularly useful in conjunction with an overall card construction having enhanced flexibility (e.g., exceeding the ISO / IEC 7810 ID-1 standard for transaction cards or meeting or exceeding the ISO / IEC 15457 standard for thin flexible cards). Flexible card constructions using OLED displays may also include a flexible circuit board. Therefore, the term "LED" as used herein with respect to a display should be interpreted as referring to either OLED or non-organic LEDs.

[0054] In other embodiments, member 1104 can be an active or dynamic member, such as described in U.S. Provisional Application Serial No. 62 / 545,630, entitled "CARDWITH DYNAMIC SHAPE MEMORY ALLOY TACTILE FEATURE," which is incorporated herein by reference. Member 1104 can differ from the body in any number of ways, including color, texture, reflectivity, opacity, and combinations thereof. Member 1104 can include a display and a processor configured to generate a dynamic security code on the display, such as described in the '711 application. Any or all of the electronic components described herein may be embedded in the card in any manner known in the art, including as described in the '711 application or in U.S. Patent No. 10,406,734, filed on October 18, 2018, which claims priority to U.S. Application Serial No. 16 / 320,597, filed on January 25, 2019, both entitled “OVERMOLDED ELECTRONIC COMPONENTS FOR TRANSACTION CARDS AND METHODS OF MAKING THEREOF,” and both applications are incorporated herein by reference.

[0055] like Figure 12 As depicted, the insert may comprise only a single member 800, wherein, when the card is assembled, the entire front-facing surface of the member is recessed relative to the body front, meaning that the plurality of windows 702-706 are tactilely perceptible in the front of the card. Thus, for example, if the insert 800 comprises mother-of-pearl, lamination of the card will not alter the physical relationship between the components. While preferably non-transparent, in some embodiments, member 800 may be transparent.

[0056] However, in Figure 13 In other depicted embodiments, the insert 1302 may include a material that is flowable at the lamination temperature and that may flow partially or completely into the plurality of openings in the body 1300 during the lamination step such that the plurality of portions 1304, 1306, 1308 of the front-facing surface of the non-transparent member protrude into the plurality of openings and are positioned flush with the front face of the body.

[0057] exist Figure 14 In other embodiments depicted in FIG, the entire front-facing surface of the non-transparent member 1402 can remain recessed relative to the body front, and a plurality of transparent or translucent members 1404, 1406, 1408 can be disposed in the openings. The transparent or translucent members can include an optically clear epoxy deposited in the openings via automated dispensing.

[0058] exist Figure 15 In other depicted embodiments, a transparent or translucent layer 1510 may be positioned above the front face of the body 1500 and above the plurality of openings such that during the lamination step, protrusions 1504, 1506, and 1508 from the layer flow fully or partially into the openings, with the layer 1502 maintaining its entirety recessed relative to the front face of the body.

[0059] like Figure 16 As described, in a multilayer body construction, an intermediate transparent or translucent adhesive layer 1610 can be disposed between the first layer 1500 and the second layer 1502 of the body such that the protrusions 1604, 1606, and 1608 flow completely or partially into the openings during the lamination step, with the layer 1620 remaining recessed in its entirety relative to the front face of the body.

[0060] like Figure 17 As depicted, during the lamination step, the transparent or translucent layers 1702 or 1704, respectively, disposed on the front and back sides of the body 1700, can flow together, fully or partially, into the openings 1710, 1712. This structure and manufacturing method may be particularly well suited for embodiments in which the openings 1710 and 1712 are slits, e.g. Figure 10B and 10C Window features 1022, 1024, 1032, 1052 are depicted in FIG. Although an upper layer and a lower layer are shown, some embodiments may have only one or the other. Although a single discrete upper layer and a single discrete lower layer are shown, some embodiments may have multiple layers on and / or under the body, and in some of these embodiments, more than one layer may contribute to filling the opening. For example, an adhesive layer, which may include a carrier with adhesive on both sides, may be interposed between the body and each of the upper and / or lower layers, and during the lamination step, the adhesive, the carrier, and the upper or lower layer may all flow into the opening. In other embodiments, the adhesive on the underside of the carrier (or directly disposed on the underside of the upper and / or lower layer) may be the only material that flows into the opening.

[0061] Despite Figure 17 , but it should be understood that the flow of material can result in convex, concave, coplanar, or irregularly shaped surfaces of the flowing material on one or both sides of the card. In any embodiment where material flows into the window / recess / slot, a convex, concave, coplanar, or irregularly shaped surface can be formed, and the overall shape can be intentionally controlled to have a specific shape. Similarly, in embodiments where an insert is pre-formed and assembled into the window / recess / slot, the insert can also conform to any of the aforementioned shapes.

[0062] although Figures 13 to 17 A monolithic body is depicted, but it should be understood that the body in these embodiments may include, for example, Figure 11 The multi-layer ontology depicted.

[0063] For example, refer to Figure 12 The method and process for manufacturing a card having a window pattern may include providing a metal, ceramic, or ceramic-coated body 700 and creating a groove 804 in the body, the groove 804 having a perimeter and extending from the back to a position adjacent to the front; then creating a plurality of openings 702, 704, 706 extending from the front into the groove, the plurality of openings forming a pattern. An insert 804 is positioned in the groove, and then a non-metallic backing layer 1206 adjacent to the back of the body and the back of the insert is laminated to the body and the insert.

[0064] In e.g. Figure 11 In some of the depicted embodiments, the step of providing a body can include providing a first layer 1100 defining a front side of the body and a second layer 1102 defining a back side of the body. In such embodiments, the step of creating a slot includes creating a through hole 1120 in the second layer 1102, and the step of creating a plurality of openings includes creating a plurality of through holes 1110a to 1110c in the first layer 1100. The openings, slots, and through holes referred to in these methods can be laser cut, milled, etched, or machined by any method known in the art. For ceramic coating embodiments, the metal or other material body or body layers can first be coated with the ceramic and then the various openings cut and the layers assembled, or the openings can first be cut in the metal or other body and / or the layers assembled, and then the ceramic coating can be applied to the outer surface before assembling the rest of the components.

[0065] like Figure 12 As depicted, the process can include creating a recessed lip 802 in the back side of the body around a slot 804, and forming an insert 800 having a stepped periphery including an outermost region 902 having a geometry configured to mate with the recessed lip 802, and an innermost periphery 904 configured to fit within the slot 804.

[0066] The step of placing the insert in the slot may include bonding the outermost area of ​​the insert to a recessed flange in the body, for example, using an adhesive or via a non-adhesive mechanical bond, such as ultrasonic welding, brazing, or soldering. The use of a flange design in conjunction with a bonding material, such as an adhesive, solder, or braze alloy, allows bonding to the flange in a manner that minimizes the amount of adhesive or other bonding material flowing into the opening in the front face of the body. However, in other embodiments, it may be desirable to cause a bonding material, such as a hard-drying clear epoxy, to flow into the openings and fill them to form, for example, Figure 14, in which case a flange may not be required. Other methods of filling the plurality of openings with a transparent epoxy resin may include automatically dispensing the epoxy resin into the openings after the insert has been put in place. Other methods of filling the openings with a transparent or translucent material may include providing a transparent or translucent coating on the front face of the body (e.g., via lamination of a solid layer, or by applying a spray coating or a liquid layer), and at least partially filling the plurality of openings with a portion of the transparent coating that flows into the plurality of openings, for example, during the lamination step.

[0067] As described above, in embodiments where the insert comprises a material that flows during lamination, the method may include performing the lamination step under sufficient heat and pressure to cause the protrusions from the insert to flow completely or partially into the plurality of openings during the lamination step. Figure 10B 、 Figure 10C and Figure 17 In embodiments with slits such as those depicted in FIG, the openings may be etched, milled, or laser generated (although not limited to any particular formation method).

[0068] like Figure 10B As depicted, for ease of manufacturing, the step of creating the gap 1032 may include creating a continuous gap defined by portions 1030 and 1032 extending from the payment module slot 1034 to the edge of the card. If it is undesirable for aesthetic reasons that portions of the gap (e.g., portion 1030) are transparent or translucent, such portions may be filled with a different type of filler (e.g., a non-transparent or translucent non-conductive filler). Such a filling step would be performed prior to the lamination step of filling the transparent or translucent window portion. As disclosed in U.S. application Ser. No. 15 / 928,813, which is incorporated herein by reference in its entirety, the continuous gap defined by portions 1030 and 1032, filled with a non-conductive card matching filler in portion 1030 and a non-conductive transparent filler in portion 1032, may be operable to enable the ground metal frame 1020 to function as an amplified antenna or coupling frame. As Figure 10C As shown, in other embodiments, the aperture 1056 emanating from the module slot 1054 in the card 1050 may be a separate element that is not integrated into the manufacture of the design defined by the transparent or translucent window 1052 .

[0069] It should be understood that Figure 10BThe depicted method of creating an extended opening and filling one portion with a transparent or translucent filler and another portion with a non-translucent / non-translucent portion is not limited to embodiments in which the gap as a whole connects the payment module slot to the edge of the card. For example, for ease of manufacturing, it may be desirable to create a continuous gap and then fill portions of the gap with different fillers for purely aesthetic reasons, and the different fillers can be of any type. For example, the filler can be transparent, translucent, opaque, conductive, non-conductive, or some combination thereof, wherein different portions of the same continuous opening (or different discrete openings) have different fillers, each filler having a different aesthetic appearance, such as a different color, a different texture, etc. If desired, the filler can include a precious metal such as gold. In other cases, the window or portion thereof can be illuminated as described herein, for example using LEDs or in any manner known in the art. The "filler" (and insert material) can completely fill or partially fill all or some of the openings in any embodiment disclosed herein.

[0070] exist Figure 18 In one embodiment depicted, a light guide layer 1825 including a light guide 1810 and a light source 1815, such as a backlight LED, can be sandwiched between metal layers 1820 and 1830. The LED 1815 is positioned adjacent to the input of the light guide, while windows 1802, 1804, and 1806 are positioned adjacent to the output surface of the light guide. Light from the LED 1815 shines into the light guide and is transmitted out through the windows 1802, 1804, and 1806. Although Figure 18 , it should be understood that embodiments in which the light guide is disposed beneath the apertures in the metal layer can be provided in any other configuration described herein. The windows 1802, 1804, 1806 can have no filler or a transparent or translucent filler and can be formed via any method or conform to any structure described herein.

[0071] In some embodiments or designs, it may be more desirable to create discrete gaps with one or more metal bridges 1026, 1028 therebetween for the overall structural stability of the card, rather than creating a continuous gap such as the circular shape formed by gaps 1022 and 1024. Figure 10B As depicted, the absence of bridges 1026 and 1028 would completely separate the central circular portion of the metal body from the remainder. However, providing metal separation between adjacent gaps is not limited to embodiments where separation is desired to be avoided.

[0072] As used herein, the term "gap" refers to the gap formed between metal edges, where the distance from edge to edge is generally small enough that it is undesirable or impractical to place a separate filler material in the gap prior to the lamination step and to minimize the risk of bubble formation during lamination. Lamination conditions can be controlled as desired so that the gap is filled by the upper and lower layers without leaving a noticeable recess or is partially filled to provide a tactilely distinguishable recess.

[0073] Other card features

[0074] In embodiments where the card body is metal or ceramic-coated metal and the transaction card includes a payment module configured for contactless interface with a card reader (e.g., where, in at least one operating mode, transaction circuitry embedded in the card is inductively coupled to the card reader using RFID technology), positioning the window adjacent to the module can enhance the card's RF performance, thereby extending the distance at which the card can be read in contactless mode. Specifically, the absence of metal adjacent to the module, and specifically near the module antenna, can significantly improve (extend) the read distance between the card and the reader required to couple the card to the reader, relative to a card without a transparent window. The optimal distance can be determined by producing multiple otherwise identical cards with different window sizes and positions and testing the differences in read distances for the different designs. Applicants have found that, generally, the percentage improvement in read distance ranges from 12% to 50%, depending on the distance between the edge of the metal card and the module within the range of 1-5 cm. Therefore, the absence of significant metal area within a distance of 1-4 cm due to the hole in the metal body to accommodate the window is expected to provide a measurable level of improvement. It should be understood that because dual interface devices operate in both "contactless" and "contact" modes, references to devices with "contactless" functionality encompass both contactless-only modules as well as dual interface capable modules.

[0075] In some embodiments, the payment module can be positioned inside a transparent window, in which case the coupling antenna can be positioned around the module using minimal visible traces inside the transparent window. In other embodiments, the entire metal card body can serve as the coupling antenna, or the coupling antenna can be embedded in the body, as is known in the art. The minimal visible traces, including the antenna traces, and the module can be obscured by or integrated into the graphical content of the printed design on the window. However, the positioning of the card reader module within the window is not limited to metal or ceramic-coated metal embodiments and may also be present in embodiments featuring an all-ceramic or ceramic-coated non-metal body.

[0076] like Figure 3As shown, the electronic device 310 and any connecting traces 330 can be provided on a surface of the window, preferably on the back surface of the window, wherein the electronic device can be further covered and protected by a backing layer. Figure 4 and Figure 5 As shown, in an alternative embodiment, the electronic devices 410, 510 may be embedded in the windows 420, 520. Figure 5 In one embodiment depicted, embedded electronics can be embedded by injection molding the electronics 510 within a transparent or translucent polymer comprising a window 520. In such an embodiment, one or more conductive members 532 connected to the electronics can be disposed in the window oriented along the thickness of the window (perpendicular to the front and back surfaces of the window) to transmit power and / or signals from the interior portion of the window to the surface 522 of the window (or a layer closer to the surface of the window), where the conductive members 532 are connected to conductive traces 530 printed on the window. An exemplary process for embedding electronics for insertion into a metal card body is described in U.S. Provisional Application Serial No. 62 / 555,367, entitled “TRANSACTION CARD WITH EMBEDDED ELECTRONIC COMPONENTS AND PROCESS FORMANUFACTURE,” which is incorporated herein by reference.

[0077] exist Figure 4 In another embodiment depicted, the electronic device can be optionally disposed on a first layer 422 of a transparent or translucent polymer, with a second layer 424 disposed thereon to encapsulate the electronic device (and optionally, one or more wires 430 for connecting to the electronic device). The multi-layer window is not limited to only two layers and can include any number of layers that can provide the desired aesthetic or functional qualities. In a multi-layer embodiment, the wires 430 can be printed on the first layer 422 before another layer (e.g., 424) is disposed.

[0078] A relatively thin non-metallic backing layer 120 (e.g., clear PVC, but not limited to any particular construction material) that is relatively thin compared to the relatively thick substrate is preferably laminated to the back of the body and the back of the window. Although not limited to any particular thickness range, transaction cards are typically standardized in size to a thickness of approximately 0.032 inches, and the body is typically in the range of 0.008 inches to 0.028 inches, preferably in the range of 0.010 inches to 0.020 inches, and more preferably in the range of 0.012 inches to 0.018 inches, with the backing layer optionally having a thickness that makes up the difference between the total thickness and the body minus the thickness of any adhesive layer or other coating.

[0079] One or more features may be printed on the body, which may include a printable metal such as printable stainless steel (e.g., stainless steel hereinafter having a coating (not shown) on at least the front face 104 to improve acceptance of printed inks on the steel surface). The coating may include, for example, a polyester-based coating that accepts UV-curable screens and inkjet inks or solvent or oxidative printing. In other embodiments, dye printing or sublimation printing may be used. For embodiments having a ceramic body or a ceramic-coated body, the ceramic may similarly be coated, roughened (e.g., chemically, mechanically, or with a laser) to accept the printed layer. Printing embodiments are not limited to any particular printing technology or technique.

[0080] like Figure 1A As depicted, the front of the card may have a decorative pattern. The decorative pattern may be a printed pattern (or, as further described below, an engraved or etched pattern), or the front may be printed with a solid color (e.g., Figure 1A The printed information may include the name of the card issuer (e.g., Citibank, Inc., USA - issued by Figure 1A The text "Bank" in the text indicates the card type and / or name (e.g. SAPPHIRE, AMERICAN etc. Figure 1A The card may be printed on a cardboard sheet or other similar cardboard element. ... Certain printed information (e.g., graphics, name of the card) may be printed in a first printing step to produce a card "blank" ready for personalization, and other printed information (cardholder, serial number, expiration date) may be printed in a second personalization printing step. The first printing step and the second printing step are typically geographically and temporally remote from each other and performed by different printing presses. The printing may extend to printing on the window insert, including printing across the interface between the perimeter of the window and the perimeter of the aperture. UV curable inks may be used for printing, but the present invention is not limited to any particular type of ink.

[0081] The front face of the body may also have decorative grooves provided in the body, for example by etching, machining, laser, etc. Thus, in one embodiment, Figure 1A The pattern shown may comprise a solid black printed substrate with grooves provided in the pattern ( Figure 1A(The pattern is depicted as a fish scale pattern in the illustration, but is not limited to any particular type of pattern, to a repeating or regular pattern, to a single pattern, or to a pattern having any particular amount of coverage—i.e., the pattern may extend across the entire card surface or may be limited to one or more distinct areas of the card.) The grooves may be filled, for example, with ink of a different color than the surface of the card, or the grooves may expose the color of the body beneath the metal or ceramic or ceramic beneath the printed layer. The grooves may penetrate only the printed layer, or they may penetrate the body. The grooves may be cut into the window and extend across the interface between the edge of the body and the window. Similarly, the printed layer on the card may extend across this interface.

[0082] Therefore, if Figure 1A , the interface 132 between the window insert 112 and the corresponding perimeter of the aperture 108 can be positioned radially within a printed feature, such as a printed solid black circle 130 surrounding the ship graphic 118, such that the print extending across the interface helps to visually weaken the interface. In another embodiment, the interface can be positioned slightly radially outside of the circle 130, such that the design imparted by the groove also extends across the interface, further weakening the interface. In embodiments where it is desired that the window be substantially free of printing, the printed content can include only a decorative perimeter outline that overlaps the interface (i.e., provided on both the window and the card body on either side of the interface), such that a substantial portion of the window positioned radially inward of the interface, or radially inward of the printed perimeter outline, is free of printing.

[0083] In some embodiments, the front side may also include an optional hard coating 140, while other embodiments may not have a coating on the printed / engraved layer or on an uncoated metal or ceramic surface on the front side of the card. The transaction card may also include a magnetic stripe 150, preferably disposed on the backing layer 120 on the back side 106 of the body 102, a signature panel 152, a hologram 154, a machine-readable code 156 (depicted as a barcode, but may include any type of machine-readable code, including but not limited to a QR code), or a combination thereof. Most embodiments also include an embedded integrated circuit (not shown) connected to contacts 160 configured to be read by a card reader, an embedded RFID antenna (not shown), or a combination thereof (for dual interface (DI) cards) to allow use with contact-based and / or contactless card readers. While the hole 108 may be purely aesthetic, the hole may be strategically located on the card to enhance the RF performance of the dual interface card.

[0084] An exemplary process for manufacturing a transaction card as described herein may include first providing a body 102 having a thickness (T), creating a hole 108 in the body having a perimeter and extending from the front face 104 of the body to the back face 106. A non-metallic backing layer 120 is positioned adjacent to the back face of the body, preferably adhered in place by an adhesive provided on the side of the backing layer facing the body, and a non-magnifying transparent insert 112 is inserted into the hole 108 in contact with the adhesive of the backing layer 120, and the components are then laminated together. The insert may be produced by any means known in the art, such as by cutting or stamping a plurality of inserts having the desired perimeter from a sheet of insert material, or by extruding a rod having the insert perimeter and cutting into small pieces based on the rod having the thickness (T).

[0085] The holes 108 can be created in the metal body by any method known in the art, such as by cutting (e.g., mechanical or laser), stamping, or etching, for example, using a computer-controlled (e.g., computer numerical control (CNC)) machine. In embodiments where the body comprises printable stainless steel (or any other coated metal where the integrity of the coating is important), a resist can be applied to the coating surface or to portions of the coating surface where it is desired to retain the coating during any acid etching step (e.g., if an etching step is used to create the holes). For example, the resist is applied to the entire surface of the metal except where the holes 108 and any other grooves or surface patterns are to be formed. After etching, the remaining resist is removed and the body is ready for further processing.

[0086] In an exemplary embodiment of a ceramic body in which the body comprises a solid ceramic, holes are preferably formed in the green state of the ceramic and then the ceramic is fired. Given the properties of the given ceramic material and the expected change in pore size during the firing process (if any), the size of the pore size before firing is selected to produce the desired post-filling pore size. Although alternative processing can involve making a ceramic blank without holes and then mechanically grinding, lasering or freezing / cracking the holes after firing, such methods are generally less efficient and are therefore not preferred. In an exemplary embodiment in which the body comprises a metal core with a ceramic coating, the metal body can be formed as described above and then the desired ceramic coating is applied to the metal. For example, a sprayed ceramic coating combined with a binder can be applied, or a ceramic can be arranged around the metal, for example, via injection molding, and then fired. In a preferred embodiment, the sprayed ceramic coating can be applied only to the front of the metal core. The body of the ceramic coating with a non-metallic core can be similarly processed.

[0087] The laminate assembly can then undergo a printing step to print the desired print on the front of the body. In an exemplary method, the printing step includes printing the print using an inkjet printer using UV curable ink and then exposing the print to UV radiation suitable for curing the ink. The front of the body can be etched or engraved with grooves before or after printing. In the process of filling the grooves with, for example, ink or metal of a different color, a groove filling step (e.g., an erasing step by erasing the filling material across the surface so that the filler (ink, metal, resin, etc.) is only deposited in the recessed portion created by the groove) can be performed after the grooves are created.

[0088] Although the above steps are described in a preferred order, it should be understood that the above steps are not limited to being performed in any particular order. For example, in some methods, the steps of cutting the holes, adhering the backing layer in place, and inserting the windows can be performed after the steps associated with printing on the front of the card, creating the grooves, etc. In other methods, the grooves can be created before printing.

[0089] like Figure 2 As depicted, each completed transaction card 100 defines a first bounded area (corresponding to the length and width of the card, minus the area of ​​any rounded edges). In metal card embodiments, the card may be formed by a plurality of card segments having a slightly larger area than the first bounded area (e.g., Figure 2 As depicted in FIG. 1 , a second area of ​​the sheet 200 slightly larger than 8X is used to manufacture the card. In such a manufacturing process, the process also includes cutting the metal sheet into a plurality of transaction cards corresponding to the multiple. Figure 2 As shown, the ratio of the second area to the first area is generally not an integer (e.g., Figure 2 depicted, a value between 8 and 9), and the multiple corresponding to the number of cards cut from the sheet may represent the nearest integer corresponding to the second area rounded down. The cutting steps for cutting the holes and cutting the individual cards from the sheet may be performed by a laser. Any groove may be machined, etched, or laser formed. Although in Figure 2 is depicted as a nearly finished card, but it should be understood that in some embodiments, the core of metal or other material can be similarly cut from a larger sheet before the ceramic coating is applied.

[0090] The integrated circuit and the connected contacts and / or antenna may be embedded in the metal card body by any method known in the art, such as described in U.S. Pat. No. 9,390,366, which is incorporated herein by reference. In embodiments where an optional hard coating is applied to the front of the card, the hard coating may be applied as a coating or as a discrete layer, such as described in U.S. Published Application No. 20140224881, also incorporated herein by reference, for its teachings of applying a hard coating to a metal card. Although described herein with reference to only certain layers, it should be understood that some embodiments may include additional layers between, on, or below the described layers, including but not limited to laminates, adhesive layers, printed content, or coatings (including but not limited to ceramic coatings).

[0091] Now refer to 19A to 19C , shows another transaction card embodiment 1900. The transaction card includes a metal layer 1910 having a front surface and a back surface and at least two openings 1920 and 1930, each extending through one or both of the front and back surfaces of the metal layer. Figure 19B In the illustrated embodiment, both openings 1920 and 1930 extend through the upper and lower surfaces of the metal layer, with opening 1920 having a relatively larger perimeter at the upper surface than at the lower surface. A transponder module 1925 (preferably a contactless or dual-interface) is disposed in opening 1920 and may rest on step 1921 between the relatively wide and relatively narrow portions of opening 1920. As is known in the art, transponder module 1925 may be disposed on or within a plug made of non-metallic material.

[0092] An LED module 1935 is disposed in the opening 1930. The LED module 1935 has a planar illumination area 1937 that is visible from a processed surface (e.g., the front surface) of the transaction card. Figure 19C As shown, in one embodiment, an LED module 1935 includes an LED 1932 (depicted as a side-emitting LED) configured to emit light and a light guide 1933 for distributing the light emitted by the one or more LEDs over an illuminated area 1937. Thus, some portions of the LED module 1934 may not be illuminated. Thus, the non-illuminated portions may be hidden behind an opaque area of ​​the overlay or printing on top of the overlay, and features of the overlay or printing thereon may be optimized to print at the interface between the perimeter of the opening 1930 and the illuminated portion 1937 of the LED module. Figure 19BAs shown, the LED module is fixed in a window 1930 that completely penetrates the metal layer from the upper surface to the lower surface, so that the lower surface of the LED module is flush with the lower surface of the metal layer, and the upper surface of the LED module is flush with the upper surface of the metal layer. In other embodiments, the LED module can be fixed in a blind slot that does not completely penetrate the metal layer from the upper surface to the lower surface. Typically, the LED module (particularly the lighting area 1950) is non-transparent or non-translucent so that anything disposed behind the LED module (e.g., the backing layer 1940 or the bottom of the blind slot) is not visible from the front of the card.

[0093] Any number of LEDs 1932 can be provided. In some embodiments, a lighting circuit for the LEDs can include at least two LEDs, with more or different LEDs illuminated as an indicator of field strength (e.g., greater field strength translates to more collected energy, and therefore more power available to the lighting circuit, which can be illuminated in various power-related ways). In some embodiments, all of the LEDs (e.g., 1932a, 1932b) can be the same color, with the circuit configured to illuminate only the first LED at a minimum field strength and illuminate both the first and second LEDs at relatively greater field strengths. In circuits with more than two such LEDs (not shown), all of the first, second, and third LEDs can be illuminated at a relatively maximum field strength. Thus, the energy range illuminated by the first LED overlaps with the entire energy range of the second LED. In a configuration with three LEDs, the energy range illuminated by the first LED overlaps with the entire energy range illuminated by each of the second and third LEDs, respectively, and the energy range illuminated by the second LED overlaps with the entire energy range illuminated by the third LED.

[0094] In other embodiments, multiple colors of LEDs can be provided, with the circuit configured to illuminate a first LED 1932a (e.g., red) corresponding to a relatively weak field strength, and illuminate a second LED 1932b (e.g., green) corresponding to a relatively strong field strength. The ranges of illumination of the two different LEDs may overlap. For example, a dual-LED arrangement can be configured to illuminate the red LED 1932a within a first power range (e.g., 1-66%) and the green LED 1932b within a second power range (e.g., 33%-100%), with both LEDs illuminated within an overlapping range (e.g., 33%-66%) to produce yellow light.

[0095] The illumination intensity can also vary based on the field strength, such that a single LED or multiple LEDs having the same wavelength can provide a brightness variation as an indicator of field strength. For example, in an embodiment where both LEDs 1932a and 1932b emit the same wavelength, the illumination intensity of LED 1932a can range from a relatively weak intensity of 1% of the field strength to a relatively strong intensity of 50%-100% of the field strength, and the illumination intensity of LED 1932b can range from a relatively weak intensity of 51% to a relatively strong intensity of 100% of the field strength. Similarly, multiple LEDs having different wavelengths can be illuminated in various combinations of one or more LEDs to produce a color spectrum based on field strength. For example, from relatively weakest to relatively strongest field strength, the LEDs can be illuminated across a spectrum (e.g., red = only red LEDs, optionally in a relatively dim to relatively bright intensity range; orange = higher red LED intensity than green LED intensity; yellow = relatively equal red and green LED intensities; yellow-green = higher green LED intensity than red LED intensity; green = only green LEDs, optionally in a relatively dim to relatively bright intensity range). The number and / or color of LEDs are not limited to any particular configuration. Those skilled in the art of electronics are familiar with the basic circuitry required to illuminate various LEDs in response to power supplied to the circuitry, and therefore, specific configurations will not be described in detail herein. The ranges and variations within these ranges are provided for illustration only and are not intended to limit the present invention in any way.

[0096] As will be understood by those skilled in the art, in use, a contactless or dual-interface transponder module is a component in a transaction circuit that is configured to communicate with a card reader (not shown), which is configured to transmit radio frequency (RF) waves having energy. As is well known in the art, the transaction circuit includes a transponder module 1925, which is configured to receive (using a receiver connected to an antenna 1986) an input RF signal 1984 transmitted by a transmitter in the card reader 1980, a transmit antenna 1982, and respond with an output RF signal 1985 transmitted by the transmitter having a transmit antenna 1988, which is received by the card reader's receiver having a receive antenna 1983. The receiver / receive antenna 1982 and the transmitter / transmit antenna 1983 may comprise a single transceiver / transceiver antenna configured for two-way communication. The transponder is typically powered by harvesting energy from the RF waves 1984 transmitted by the card reader 1980. The transponder typically has its own power generation circuit, similar to the circuit described below with respect to the power supply for the LED module. In other embodiments, power can be provided by an actively driven RF transceiver with a power supply (e.g., a battery) installed in the device, and / or the LED can also have (or share with the transponder) a power supply installed in the device.

[0097] LED module 1933 includes one or more components in a lighting circuit that is also powered by energy harvested from RF waves 1984. The lighting circuit includes a power supply 1990 including energy harvesting circuitry (configured to generate AC or DC power); LEDs 1932; and one or more surface mount technology (SMT) components 1938. The lighting circuit (e.g., one or more SMT components) may include a charge pump (also known as a voltage pump or voltage generator), as is well known to those skilled in the art, for boosting the operating voltage of the lighting circuit above the voltage of the RF waves. Any type of circuitry for boosting or lowering voltage may be provided. In some embodiments, the lighting circuit and transaction circuitry are isolated from each other, such that the lighting circuitry is configured to illuminate independently of the status of a transaction being executed by the transaction circuitry. As used herein, the term "transaction circuitry" refers to any circuitry used to process a transaction. In payment devices (credit cards, debit cards), the transaction circuitry may comprise conventional payment circuitry configured to exchange payment information between the card and a card reader, ultimately debiting the payer's account and crediting the payee's account. However, suitable transactions are not limited to payment transactions and may include any information exchange between a card and a card reader that ultimately results in a record of information. For example, a casino membership card may track the amount of money a user has wagered, won, or lost; this record is a "transaction," while the membership card does not actually manage the payments associated with the wagers, wins, or losses. Therefore, as used herein, the term "transaction circuitry" should be understood to refer to any information exchange associated with any type of transaction, including but not limited to payment circuitry. In other embodiments, the lighting circuitry and the transaction circuitry comprise components of a unified circuit, wherein the lighting circuitry is configured to illuminate in a manner that indicates the status of a transaction executed by the transaction circuitry. In yet other embodiments, where the transaction circuitry and the lighting circuitry are not otherwise interconnected (i.e., illumination is independent of the status of the transaction), the transaction circuitry and the lighting circuitry may share power from a single energy harvesting source.

[0098] An exemplary simple energy harvesting circuit 1900 is schematically depicted in the enlarged region of FIG19 and, as is known in the art, generally includes a receiving antenna 1991 for receiving RF waves from a source (in this case, waves 1984 from a card reader 1980), attached to a rectifier / voltage multiplier 1994, a capacitor (or battery) 1995 in parallel with one or more resistors 1992 disposed between the antenna 1991 and ground 1993, and generating a direct current (DC) voltage between two poles 1996 and 1997. This DC voltage powers the connected circuitry. Additional components, such as an impedance matching network (IMN) (not shown) between the antenna and the rectifier and / or any other logic or other circuit components known in the art for power harvesting applications, may also be included in the circuit 1900.

[0099] like Figure 19A and Figure 19B As shown, the metal layer 1910 has a first discontinuity 1902 extending from the perimeter of the card to the opening 1920 and a second discontinuity 1904 extending from the perimeter of the card to the opening 1930. The card 1900 also includes a rear non-metallic layer 1940 disposed on the rear surface of the metal layer 1910 and a front non-metallic layer 1950 disposed on the front surface of the metal layer. A pattern 1960 (e.g., words, logos, or graphics printed or otherwise disposed on or in the front non-metallic layer 1950) covers an illumination area 1937 of the LED module that is positioned to be backlit by the LED module. Although Figure 19B 1960 (e.g., from printed ink disposed on layer 1950), but the pattern may include opaque portions of the non-metallic layer 1950 itself, or a negative pattern formed by holes in an otherwise opaque non-metallic layer 1950. The pattern may be a variety of colors. The metal layer 1910 may be used as a booster antenna connected to one of the two antennas 1986, 1991 to boost the signal received from the card reader, or may be isolated from one or both of the payment and / or lighting circuits.

[0100] The location of the LED module and opening 1930 proximate to the transponder module 1925 can provide improved RF performance of the card relative to a card without a window. Likewise, the first discontinuity 1902 and the second discontinuity 1904 can also improve RF performance relative to a card without a discontinuity.

[0101] While the invention has been illustrated and described herein with reference to specific embodiments, it is not intended that the invention be limited to the details shown, but rather that various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.

Claims

1. A transaction card having opposing machined surfaces and a peripheral edge, the transaction card comprising: a metal layer having opposing surfaces and at least two openings, each opening extending through one or both of the opposing tooled surfaces, wherein the metal layer has at least one discontinuity extending from a periphery of the card to at least one of the at least two openings in the metal layer; a transponder module disposed in one of the at least two openings in the metal layer, the transponder module comprising components in a transaction circuit, the components being configured to wirelessly communicate with a card reader, the card reader being configured to transmit radio frequency (RF) waves having energy, the transaction circuit being configured to receive an input RF signal from the card reader, to respond by outputting an RF signal, and to power the transaction circuit by harvesting energy from the RF waves; a light emitting diode (LED) module disposed in another of the at least two openings in the metal layer and having a planar illumination area visible from the processed surface of the transaction card, the LED module comprising one or more LEDs configured to emit light, the LED module including a component of a lighting circuit configured to harvest energy from the radio frequency waves to power the one or more LEDs; and At least one discontinuity is connected to and extends between the at least two openings.

2. The transaction card according to claim 1, wherein: The illumination circuit is configured to illuminate independently of a status of a payment transaction performed by the transaction circuit.

3. The transaction card according to claim 1, wherein: The illumination circuit and the transaction circuit comprise components in a unified circuit in which the illumination circuit is configured to illuminate in a manner indicative of a status of a payment transaction performed by the transaction circuit.

4. The transaction card according to claim 1, wherein: The metal layer has a first discontinuity extending from the periphery of the card to the opening containing the transponder module and a second discontinuity extending from the periphery of the card to the opening containing the light emitting diode module.

5. The transaction card of claim 1, further comprising at least one non-metallic layer disposed on each of the opposing surfaces of the metallic layer.

6. The transaction card of claim 1, further comprising a printed pattern covering the illumination area of ​​the light emitting diode module.

7. The transaction card of claim 1, wherein: The lighting circuit is configured to have variable lighting characteristics that depend on characteristics of the harvested energy.

8. The transaction card according to claim 7, wherein: The lighting circuit includes at least one light emitting diode having variable intensity, wherein the light emitting diode is configured to illuminate at a first intensity in response to collected energy within a first range, and to illuminate at a second intensity in response to collected energy within a second range, wherein the first intensity is relatively lower than the second intensity, and the first range is relatively lower than the second range.

9. The transaction card according to claim 7, wherein: The lighting circuit has at least two light-emitting diodes and is configured to illuminate one of the at least two light-emitting diodes in response to collected energy within a first range, and to illuminate another of the at least two light-emitting diodes in response to collected energy within a second range, wherein the first range is relatively lower than the second range.

10. The transaction card of claim 9, wherein: A third range is between the first range and the second range, such that the lighting circuit is configured to illuminate both of the at least two light emitting diodes when the harvested energy is within the third range.

11. The transaction card of claim 7, wherein: The at least two light emitting diodes are each configured to emit light of the same wavelength.

12. The transaction card of claim 9, wherein: At least one of the at least two light emitting diodes is configured to emit light of a different wavelength than another of the at least two light emitting diodes.

13. The transaction card of claim 12, wherein: One of the at least two light emitting diodes is configured to generate wavelengths in the green visible spectrum, and another of the at least two light emitting diodes is configured to generate wavelengths in the red visible spectrum.

14. The transaction card of claim 13, wherein: The lighting circuit is configured to illuminate red in response to harvested energy within the first range, illuminate a green LED in response to harvested energy within the second range, and illuminate both the red LED and the green LED in response to harvested energy in a third range between the first range and the second range.

15. The transaction card of claim 14, wherein: One or both of the red LED and the green LED are configured to illuminate at a variable intensity.

16. The transaction card of claim 1, wherein: The light emitting diode module further comprises a light guide for distributing light emitted by the one or more light emitting diodes over the illumination area.

17. A transaction card having opposing machined surfaces and a peripheral edge, the transaction card comprising: a metal layer having opposing surfaces and at least two openings, each opening extending through one or both of the opposing tooling surfaces; a transponder module disposed in one of the at least two openings in the metal layer, the transponder module comprising components in a transaction circuit, the components being configured to wirelessly communicate with a card reader, the card reader being configured to transmit radio frequency (RF) waves having energy, the transaction circuit being configured to receive an input RF signal from the card reader, to respond by outputting an RF signal, and to power the transaction circuit by harvesting energy from the RF waves; a light emitting diode (LED) module disposed in another of the at least two openings in the metal layer and having a planar illumination area visible from the processed surface of the transaction card, the LED module comprising one or more LEDs configured to emit light, the LED module including a component of a lighting circuit configured to harvest energy from the radio frequency waves to power the one or more LEDs; Wherein, the light emitting diode module comprises an organic light emitting diode (OLED) module; and The light emitting diode module is located in the metal layer at a position that improves the radio frequency performance of the transponder module compared to a card without the light emitting diode module.

18. The transaction card of claim 17, wherein: The illumination circuit is configured to illuminate independently of a status of a payment transaction performed by the transaction circuit.

19. The transaction card of claim 17, wherein: The illumination circuit and the transaction circuit comprise components in a unified circuit in which the illumination circuit is configured to illuminate in a manner indicative of a status of a payment transaction performed by the transaction circuit.

20. The transaction card of claim 17, wherein: The metal layer has a first discontinuity extending from the periphery of the card to the opening containing the transponder module and a second discontinuity extending from the periphery of the card to the opening containing the light emitting diode module.

21. The transaction card of claim 17, further comprising at least one non-metallic layer disposed on each of the opposing surfaces of the metallic layer.

22. The transaction card of claim 17, further comprising a printed pattern covering the illuminated area of ​​the light emitting diode module.

23. The transaction card of claim 17, wherein: The light emitting diode module further comprises a light guide for distributing light emitted by the one or more light emitting diodes over the illumination area.

24. The transaction card of claim 17, wherein: The lighting circuit includes a voltage step-up or voltage step-down component.

25. The transaction card of claim 24, wherein: The lighting circuit includes a charge pump.

26. A transaction card comprising: a metal layer having a visual appearance, a thickness, a metal layer front side, a metal layer back side, and one or more windows or slots extending through at least the front side; a transponder module and an insert disposed in the one or more windows or slots, respectively, the insert having an insert front face visible through the windows, the insert front face having a different visual appearance than the metal layer; One or more non-functional features that contrast with the visual appearance of a front-facing surface of the insert disposed below the non-functional features, the one or more non-functional features being visible from the front surface of the card, wherein the insert is one of: (a) non-transparent and non-translucent; or (b) transparent or translucent and configured to transmit backlighting to the non-functional features through the rear surface of the card; The interposer is located in the metal layer at a position that improves the radio frequency performance of the transponder module relative to a card without the interposer; and The insert comprises an illuminable light emitting diode display, and the illuminable light emitting diode display comprises an organic light emitting diode module.

27. The transaction card of claim 26, wherein: The non-functional features include printed features.

28. The transaction card of claim 26, wherein: The insert is non-transparent and non-translucent, but has an illuminable front-facing surface.

29. The transaction card of claim 26, wherein: The illuminable light emitting diode display is powered by energy harvested from radio frequency waves.

30. The transaction card of claim 26, wherein: The metal layer has at least two openings, wherein the transponder module is arranged in one of the at least two openings, and the insert is arranged in the other of the at least two openings.

31. The transaction card of claim 30, wherein: The transponder module includes transaction circuitry configured to inductively couple the transponder module to a card reader using RFID technology.

32. The transaction card of claim 26, wherein: The illuminable light emitting diode display is configured to illuminate as an indicator of card operability.

33. The transaction card of claim 26, wherein: The illuminable light emitting diode display is configured to illuminate independently of a status of a payment transaction being performed by the transaction circuitry.

34. The transaction card of claim 26, wherein: The insert is translucent or transparent and the window extends from the front surface of the metal layer to the back surface of the metal layer so that non-collimated light passes through the insert to provide contrast with the one or more non-functional features visible from the front surface of the card.

35. The transaction card of claim 26, wherein: The non-functional feature includes at least one of: a printed feature, an engraved feature, an etched feature, or a cut feature.

36. The transaction card of claim 26, wherein: The window or slot comprises: a plurality of openings in the front face of the metal layer, the plurality of openings defining the one or more non-functional features disposed within a first region, at least one opening in the back face of the body aligned with the first region, and the insert disposed in at least one opening in the back face of the body, positioned so that the front-facing surface of the insert is recessed relative to the front face of the metal layer such that the front-facing surface of the insert is visible through the plurality of openings in the front face of the metal layer.

37. The transaction card of claim 26, further comprising a backing layer laminated to a back side of the body.

38. The transaction card of claim 26, wherein: The insert, or a portion of the opening containing the insert, is partially obscured by printed or decorative content.

39. The transaction card of claim 26, further comprising a first discontinuity extending from a perimeter of the card to an opening containing the transponder module and a second discontinuity extending from the perimeter of the card to an opening containing the light emitting diode module.

40. The transaction card of claim 26, wherein: The illuminable LED display includes one or more LEDs configured to emit light and a light guide for distributing light emitted by the one or more LEDs over an illuminated area of ​​the front-facing surface of the insert.

41. The transaction card of claim 29, wherein: The illuminable light emitting diode display has variable illumination characteristics depending on the amount of harvested energy.

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