Transaction card with internal magnetic stripe

Abstract

A transaction card having an internal magnetic stripe is disclosed. A transaction card is provided. The transaction card includes a card frame having a card inlay and a card housing. The transaction card further includes a magnet disposed within the card frame between the card inlay and the card housing.

Description

[0001] This application is a divisional application of the application for patent application with the application date of September 8, 2017, application number 201710806626.5, and the title of "Transaction Card with Internal Magnetic Stripe". TECHNICAL FIELD

[0002] The disclosed embodiments relate generally to transaction cards, and more specifically, to transaction cards with internal magnetic stripes. BACKGROUND

[0003] This application claims priority to U.S. Provisional Patent Application Serial No. 62 / 385,220, filed September 8, 2016, the contents of which are incorporated herein in their entirety.

[0004] Transaction cards, such as credit cards and debit cards, have gradually become the primary means by which users complete financial transactions. Typically, transaction cards are cut from a laminate sheet of polyvinyl chloride (PVC) or polycarbonate (PC) or other similar material. After the overall shape of the card is formed, the card can be modified to add functionality and / or visual features. For example, a magnetic stripe and / or a microchip can be affixed to one side, the card is embossed with a card number and user name, and color or design can be added for aesthetics. The magnetic stripe is typically affixed to the outer surface of the card.

[0005] As transaction cards have become more popular, expectations for transaction card quality have increased. Transaction cards have gradually been made to meet higher standards in terms of material, durability, and particularly security. For example, in traditional transaction cards, the magnetic stripe is exposed on the outside of the card, making it vulnerable to damage. The magnetic stripe can be relatively easily removed, and the encoded information relating to the account recorded on the magnetic stripe can be quickly stolen by low-cost reading devices.

[0006] The present disclosure is directed to overcoming one or more of the problems set forth above and / or other problems associated with conventional / legacy transaction cards. SUMMARY

[0007] The disclosed embodiments include a transaction card. The transaction card housing includes a card frame having a card inlay and a card shell. The transaction card can further include a magnetic stripe, the magnet disposed within the card frame, between the card inlay and the card shell.

[0008] The transaction card can further include, in some aspects, a pocket to house the magnet. The pocket can be defined by the card inlay or the card shell. In some aspects, the pocket can be defined by an inner surface of the card inlay or an inner surface of the card shell. In some aspects, a first portion of the pocket can be defined by an inner surface of the card inlay and a second portion of the pocket can be defined by an inner surface of the card shell.

[0009] In some aspects, the transaction card can further include a card frame having a first curved shape and a magnetic stripe having a second curved shape. In some aspects, the magnetic stripe can be located at a distance of 100-190 microns from an outer surface of the card inlay or the card shell. In some aspects, the magnetic stripe can be a high output magnetic stripe.

[0010] In some aspects, the transaction card can further include a stripe indicator located on an outer surface of the card frame. In some aspects, the stripe indicator can be located at the same position from an edge of the card frame as the magnetic stripe.

[0011] With respect to another disclosed embodiment, a method of manufacturing a transaction card is provided. The method can include forming a card inlay, forming a card shell, forming a pocket in at least one of the card inlay and the card shell, disposing a magnetic stripe on at least one of an inner surface of the card inlay and an inner surface of the card shell at a location corresponding to the pocket, and attaching the card inlay to the card shell to form a card frame. In some aspects, the magnetic stripe can be disposed within the card frame, between the card inlay and the card shell, and within the pocket.

[0012] In some aspects, the method can further include forming a stripe indicator on an outer surface of the card inlay or the card shell to indicate a location of the magnetic stripe within the card frame. In some aspects, the method can further include forming the stripe indicator at the same position from an edge of the card frame as the magnetic stripe.

[0013] In some aspects, the method can further include forming the card inlay and the card shell by an injection molding process. In some aspects, the method can further include forming the pocket by an injection molding process. In another aspect, the method can further include forming the pocket by a computer numerical control (CNC) process after the injection molding process.

[0014] In some aspects, the method can further include forming the pocket in an inner surface of the card shell or forming the pocket in an inner surface of the card inlay. In some aspects, the method can further include forming a first portion of the pocket in an inner surface of the card inlay and forming a second portion of the pocket in an inner surface of the card shell.

[0015] In some aspects, the method can further include disposing the magnetic stripe at a distance of 100-190 microns from an outer surface of the card inlay or the card shell.

[0016] With another disclosed embodiment, a transaction card is provided. The transaction card shell includes a curved card frame having a card inlay and a card shell body. The transaction card can further include a first recessed portion in the card inlay and a second recessed portion in the card shell body corresponding to the first recessed portion. In some aspects, the first recessed portion and the second recessed portion can together form a pocket. The transaction card can further include a curved magnetic stripe that can be disposed within the pocket. The transaction card can further include a stripe indicator disposed on an outer surface of the card frame.

[0017] In some aspects, the transaction card can further include a magnetic stripe that occupies an entire space of the pocket such that the magnetic stripe is constrained in at least a thickness direction. In some aspects, the transaction card can further include an adhesive layer within the pocket. The magnetic stripe can be secured to the first recessed portion or the second recessed portion by the adhesive layer. The magnetic stripe can be located at a distance of 100-190 microns from an outer surface of the card inlay or the card shell body.

[0018] In some aspects, the card frame of the transaction card can have a curvature that is the same as a curvature of the magnetic stripe. In other aspects, the curvature of the card frame and the curvature of the magnetic stripe can be different.

[0019] The transaction card can further include a stripe indicator having a color that is different from a color of an outer surface of the card frame. In other aspects, the stripe indicator can have a printed pattern that is present on the outer surface of the card frame. In some aspects, the stripe indicator can have a texture that is different from a texture of the outer surface of the card frame. The stripe indicator can further include an icon or text. The icon or text can indicate a location of the magnetic stripe.

[0020] With another disclosed embodiment, a method of manufacturing a transaction card is provided. The method can include forming a curved card frame. The card frame can include a card inlay and a card shell body. The method can further include forming a first recessed portion in the card inlay, forming a second recessed portion in the card shell body corresponding to the first recessed portion, attaching the card inlay to the card shell body to form a pocket defined by the first recessed portion and the second recessed portion, disposing a curved magnetic stripe within the pocket, and disposing a stripe indicator on an outer surface of the card frame.

[0021] In some aspects, the method can further include providing a magnetic stripe that occupies an entire space of the pocket such that the magnetic stripe is constrained in at least a thickness direction. In some aspects, the method can further include disposing an adhesive layer within the pocket and securing the magnetic stripe to the first recessed portion or the second recessed portion by the adhesive layer. The magnetic stripe can be located at a distance of 100-190 microns from an outer surface of the card inlay or the card shell body. In some aspects, the magnetic stripe can have a curvature that is the same as a curvature of the card frame. In other aspects, the magnetic stripe can have a curvature that is different from the curvature of the card frame.

[0022] In some aspects, the method can further include disposing a strip indicator having a color different from a color of the outer surface of the card frame. In some aspects, the strip indicator has a printed pattern not present in the outer surface of the card frame. In other aspects, the strip indicator can have a texture different from a texture of the outer surface of the card frame. In some aspects, the strip indicator can have an icon or text. The icon or text can indicate the location of the magnetic strip.

[0023] It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed embodiments as claimed. BRIEF DESCRIPTION OF DRAWINGS

[0024] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description, serve to explain the disclosed embodiments. In the drawings:

[0025] Figure 1 is a block diagram of an exemplary transaction card with respect to disclosed embodiments;

[0026] Figure 2 illustrates an exemplary transaction card with respect to disclosed embodiments;

[0027] Figure 3 is a top view of a conventional transaction card;

[0028] Figure 4 is a top view of an exemplary transaction card with respect to disclosed embodiments;

[0029] Figure 5A and 5B shows a cross-sectional view of the exemplary transaction card shown in Figure 4 taken along line A-A of Figure 4 with respect to different disclosed embodiments;

[0030] Figure 6A schematically shows an exemplary magnetic strip attached to an inner surface of a card inlay with respect to disclosed embodiments;

[0031] Figure 6B schematically shows an exemplary magnetic strip 410 attached to an inner surface of a card housing with respect to disclosed embodiments;

[0032] Figure 7 illustrates a cross-sectional view of the exemplary transaction card shown in Figure 4 taken along line A-A of Figure 4 with respect to different disclosed embodiments;

[0033] Figure 8A and 8B showsFigure 4 a cross-sectional view taken along line A-A of the exemplary transaction card shown in Figure 4

[0034] Figure 9A and 9B shows a top view of an exemplary transaction card in accordance with the disclosed embodiments;

[0035] Figure 10 is a flowchart showing an exemplary method for manufacturing a transaction card in accordance with the disclosed embodiments. DETAILED DESCRIPTION

[0036] Reference will now be made in detail to the disclosed embodiments, examples of which are illustrated in the accompanying drawings. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0037] The disclosed embodiments include cards, such as transaction cards, and methods for manufacturing the cards. As used herein, the term "transaction card" refers to a card configured to provide information, such as financial information (e.g., card number, account number, account balance, etc.), quasi-financial information (e.g., rewards balance, discount information, etc.), and / or personal identification information (e.g., name, address, etc.) when read by a card reader. Examples of transaction cards include, but are not limited to, credit cards, debit cards, gift cards, rewards cards, frequent traveler cards, merchant-specific cards, discount cards, etc. The term "transaction card" can include identification cards such as passport cards, driver's licenses, access point cards, etc. The physical attributes of the transaction card (e.g., dimensions, flexibility, location of various components included in the card) can meet various international standards, including, for example, ISO / IEC 7810, ISO / IEC 7811, ISO / IEC 7812, ISO / IEC 7813, ISO / IEC 7816, ISO 8583, ISO / IEC 4909, and ISO / IEC 14443. For example, in accordance with ISO / IEC 7810, a transaction card can have dimensions of 85.60 mm (width) by 53.98 mm (height) by 0.76 mm (thickness).

[0038] ​The disclosed embodiments can improve the security of a transaction card by embedding a magnetic stripe within the card, for example, between two pieces of a card structure (a card shell and a card insert). By placing the magnetic stripe within the card, it is more difficult to steal the information stored in the magnetic stripe. Any attempt to remove the magnetic stripe from the card can damage the magnetic stripe or otherwise damage other components of the card. In addition, placing the magnetic stripe within the card protects the magnetic stripe from other external objects, thereby reducing wear and tear. Furthermore, by placing the magnetic stripe within the card, the magnetic stripe can be more securely affixed to the card. Placing the magnetic stripe within the card also eliminates the potential problem of delamination in existing card designs that can be caused by flexing (e.g., bending) or wear and tear of the card. Finally, by placing the magnetic stripe within the card, more space is available on the surface of the card for decorative design to provide better aesthetics.

[0039] Figure 1 An example transaction system 100 is shown. The transaction system 100 can include a computing system configured to receive and transmit information between components of the transaction system 100 and components outside of the transaction system 100. The transaction system 100 can include a financial services provider system 110 and a commerce system 120 that communicate with each other over a network 130. The transaction system 100 can include additional and / or alternative components.

[0040] The financial services provider system 110 can include one or more computer systems associated with an entity that provides financial services. For example, the entity can be a bank, a credit union, a credit card issuer, or other type of financial services entity that generates, provides, manages, and / or maintains financial services accounts for one or more customers. The financial services accounts can include, for example, credit card accounts, checking accounts, savings accounts, loan accounts, rewards accounts, and any other type of financial services account. The financial services accounts can be associated with physical financial services transaction cards, such as credit or debit cards that customers use to perform financial services transactions, such as purchasing goods and / or services online or at a point-of-sale (POS) terminal. The financial services accounts can also be associated with electronic financial products and services, such as digital wallets or similar accounts that can be used to perform electronic transactions, such as online purchases of goods and / or services.

[0041] Merchant system 120 may include one or more computer systems associated with a merchant. For example, merchant system 120 may be associated with an entity that provides goods and / or services (e.g., a retail store). A merchant may include a physical location that customers can physically access and that customers can use transaction cards to purchase goods and services. Such a physical location may include computing devices (e.g., merchant system 120) that execute financial service transactions with customers (e.g., POS terminals, kiosks, etc.). Alternatively or additionally, merchant system 120 may be associated with a merchant that provides an e-shopping environment such as a website or other online platform, which consumers can access using a computer via a browser, mobile application, or similar software. Merchant system 120 may include client devices, such as laptops, desktop computers, smartphones, or tablets, which customers can operate to access the e-shopping establishment.

[0042] Network 130 may include any type of network configured to facilitate communication and data exchange between components of trading system 100 (e.g., financial service provider system 110 and merchant system 120). Network 130 may include a local area network (LAN) or a wide area network (WAN), such as the Internet. Network 130 may be a single network or a combination of networks. Network 130 is not limited to the examples above, and trading system 100 may employ any type of network that allows entities of trading system 100 (shown and not shown) to exchange data and information.

[0043] Transaction system 100 can be configured to conduct transactions using transaction card 140. In some embodiments, financial service provider system 110 can provide transaction card 140 to customers for transactions associated with a customer's financial services account. For example, a customer can use transaction card 140 to make a purchase at a merchant location. During the purchase process, information can be transferred from transaction card 140 to merchant system 120 (e.g., point-of-sale). Merchant system 120 can communicate with financial service provider system 110 via network 130 to verify information and complete or reject the transaction. For example, merchant system 120 can receive account information from transaction card 140. Merchant system 120 can transmit account information, purchase amount, and other transaction information to financial service provider system 110. Financial service provider system 110 can complete the transaction by transferring funds from the customer's financial services account to a financial services account associated with the merchant.

[0044] While transaction system 100 and transaction card 140 are depicted and described in relation to transactions involving customers, merchants, and financial service providers, it should be understood that these entities are used only as examples to illustrate one environment in which transaction card 140 may be used. Furthermore, it should be understood that transaction card 140 is not limited to financial products and can be any physical card product configured to provide information to another device. For example, transaction card 140 could be an identity card configured to provide information to a device to identify the holder of a card (e.g., a driver's license) or to provide information about the holder of a card (e.g., an insurance card).

[0045] In some embodiments, the transaction card 140 may further include a transaction component 144 disposed on or in a transaction card frame (“card frame”) 142. As used herein, a “transaction component” may be one or more means and / or elements configured to receive, store, process, provide, transfer, send, delete, and / or generate information. For example, the transaction component 144 may be a microchip (e.g., Europay, MasterCard, and Visa (EMV) chip), a communication device (e.g., a near field communication (NFC) antenna, a Bluetooth device, a WiFi device), a magnetic stripe, a barcode, a quick response (QR) code, or a combination thereof. The transaction component 144 may be secured (or fastened, attached) to the card frame 142 in a manner that allows the card frame 142 to carry the transaction component 144 while maintaining the utility of the transaction component 144 (i.e., allowing the transaction component 144 to interact with the merchant system 120).

[0046] Figure 2 An exemplary transaction card 140 with respect to the disclosed embodiments is shown. Figure 2 In some embodiments, the transaction card 140 includes a two-piece structure. For example, the card frame 142 may include two separate, independently removable card components: a lower card component 202 and an upper card component 204. The lower and upper card components 202, 204 may be referred to as the first and second card components, or vice versa. Although the lower and upper card components 202 and 204 are shown as having a planar (e.g., flat) shape, it should be understood that one or both of them may have a curved shape (e.g., having a curved surface).

[0047] In one embodiment, the card frame 142 may include a structure in which a lower card member 202 forms a cavity or space 206 (therefore, the lower card member 202 may be referred to as a "card housing") and an upper card member 204 forms an inlay member configured to be placed within the space 206 (therefore, the upper card member 204 may also be referred to as a "card inlay"). However, it should be understood that other configurations are possible. For example, the transaction card 140 may include a "bucket and lid" structure, wherein the lower card member 202 forms a container and the upper card member 204 forms a lid, the lid being configured to close the container and resting on the edge of the lower card member 202. The lower card member 202 and the upper card member 204 may be fixed to each other to at least partially define the space 206 to accommodate the transaction member 144.

[0048] The lower card holder 202 and the upper card holder 204 can be permanently or temporarily attached to each other to form a complete card frame 142. For example, the lower card holder 202 can be attached to the upper card holder 204 using adhesive or by secondary molding, press fit, interference fit, snap-fit, tongue and groove, post hole, etc. If the lower card holder 202 and the upper card holder 204 are temporarily attached to each other, attachment features (e.g., hinge attachments, sliding attachments, etc.) may be included to allow the card frame 142 to be detached. Other techniques for attaching the lower card holder 202 to the upper card holder 204 will be apparent to those skilled in the art.

[0049] In some embodiments, such as Figure 2 As shown, the transaction component 144 may include a first transaction component 230 and a second transaction component 235 located within the enclosed space 206. The first transaction component 230 may be a microchip, and the second transaction component 235 may be a near-field communication (NFC) antenna. It should be understood that the first transaction component 230 and the second transaction component 235 are examples, and other configurations are possible (e.g., the transaction card 140 may include additional and / or alternative transaction components, or may include only one of the first and second transaction components 230 and 235).

[0050] Figure 3 This is a top view of a traditional transaction card 300. The top view can be either a front or rear view of the traditional transaction card 300. For example... Figure 3 As shown, a conventional transaction card 300 includes a card frame 305 and a magnetic stripe 310 disposed on the outer surface of the card frame 305. The magnetic stripe can be disposed on the front or back side of the card frame 305. In any configuration, in a conventional transaction card, such as Figure 3 As shown, the magnetic stripe is fixed to the outside of the card frame and exposed on the outside of the card frame.

[0051] For traditional transaction cards, current industry practice uses adhesives to apply an overlay to the card surface (including the magnetic stripe). The current overlays used in industry are thin enough to allow the reader to read the magnetic stripe. The overlay also serves as an additional holding mechanism to retain the magnetic stripe on the card. However, after the card frame with the magnetic stripe has already been manufactured, the overlay is typically applied during the card printing process (e.g., by a card printer). This additional process of applying the overlay increases the cost of card production.

[0052] In traditional card manufacturing processes, injection molding is typically not used. Therefore, while industry practice may use thicker layers to improve the protection and retention of the magnetic stripe, the card manufacturing industry has not yet considered a technology that incorporates the magnetic stripe within the card during the manufacturing process.

[0053] Figure 4 This is a top view of an exemplary transaction card 400 with respect to the disclosed embodiments. Figure 4 As shown, the transaction card 400 includes a card frame 405 and a magnetic stripe 410 disposed within the card frame (dashed lines indicate that the magnetic stripe 410 is disposed within the card frame). The magnetic stripe 410 can be disposed at a position corresponding to the location where a conventional magnetic stripe would appear on the card. For example, the magnetic stripe 410 can be disposed 1-3 mm inward from the outer edge of the transaction card 400 (e.g., at a distance of...). Figure 4 The distance d from the top edge shown can be 1-3 mm. The shape of the transaction card 400 can be any suitable shape, such as rectangle, triangle, circle, or any combination of shapes. The size of the magnetic stripe 410 can be any suitable size. For example, the size of the magnetic stripe 410 can follow... Standard or ISO standard.

[0054] Figure 5A and 5B The following are shown regarding different disclosed embodiments. Figure 4 The line AA is intercepted Figure 4 A cross-sectional view of an exemplary transaction card 400 is shown. Figure 5A and 5B The illustration shows a magnetic stripe 410 disposed within a card frame 405. In a two-piece structure, the card frame 405 may include a first card component 411 (also referred to as a "card insert 411") and a second card component 412 (also referred to as a "card housing 412"). The card frame 405 may be similar to... Figure 2 The card frame 142 shown.

[0055] Now for reference Figure 5A In order to accommodate the magnetic strip 410 arranged in the card frame 405, a pocket or cavity (e.g., pocket 420) may be formed in at least one of the card insert 411 or card housing 412. Figure 5A The structure in which the bag 420 is formed in the insert 411 is shown. Figure 5BThe configuration in which a pouch 420 is formed in a card housing 412 is shown. (See diagram) Figure 5A and 5B As shown, the magnetic stripe 410 is arranged inside the pocket 420 and fixed to the card insert 411. Figure 5A (as shown) or card housing 412 ( Figure 5B The inner surface of the bag (shown). Although the magnetic strip 410 is shown to occupy less than the entire space 420, it should be understood that the magnetic strip 410 may occupy the entire space of the bag 420.

[0056] A pouch 420 may be formed in the inner surface of at least one of the card insert 411 or card housing 412. The inner surfaces of the card insert 411 and card housing 412 are the respective surfaces that face each other when they are attached to each other to form the card frame 405. The pouch 420 may be formed during a molding process (e.g., injection molding process) when the card frame 405 (e.g., the card insert 411 and card housing 412) is manufactured. For example, the pouch 420 may be formed in the same injection molding process as the card insert 411 and / or card housing 412. Alternatively or additionally, the pouch 420 may be formed after the card frame 405 (e.g., card housing 412 and / or card insert 411) is formed, for example by a computer numerical control (CNC) machining process. After the card frame 405 (e.g., the card insert 411 and / or card housing 412) is formed, the pouch 420 may be formed in the card insert 411 and / or card housing 412 by a separate CNC machining process. CNC machining processes can include milling, laser cutting, grinding, lathe work, etc. For example, a portion of material can be removed from the inner surface of the insert 411 and / or the inner surface of the housing 412 to form a pocket 420.

[0057] In one embodiment, such as Figure 5B As shown, the pouch 420 is formed in the inner surface of the card housing 412 by injection molding or machining. A magnetic stripe 410 may be disposed within the pouch 420. For example, after the pouch 420 is formed in the card housing 412, an adhesive layer (not shown) may be placed in the pouch 420. The magnetic stripe 410 may be placed on the adhesive layer and secured to the inner surface of the card housing 412 by the adhesive layer. The card insert 411 and the card housing 412 may then be assembled (e.g., attached) together to form a card frame 405, wherein the magnetic stripe 410 is positioned within the pouch 420. Figure 5BThe diagram schematically illustrates a magnetic stripe 410 positioned within a pocket 420 disposed on the inner surface of a card housing 412 when a card frame 405 is formed. In some embodiments, an adhesive layer may be omitted. The magnetic stripe 410 may be placed within the pocket 420 and is securely held by the card insert 411 and the card housing 412 when they are attached to each other to form the card frame 405. It should be understood that when an adhesive layer is not used, the magnetic stripe 410 may occupy the entire space of the pocket 420, at least in the thickness direction of the card frame 405, such that the magnetic stripe 410 is constrained at least in the thickness direction.

[0058] Based on the amplitude of the magnetic stripe's output signal, magnetic stripes are classified into low-output and high-output stripes. "High output" refers to a signal amplitude from the magnetic stripe that is higher than a predetermined threshold when read by a card reader (e.g., greater than 100% of the ISO output specification, such as 130%, 150%, 160%, 180%, etc.). "Low output" refers to a signal amplitude from the magnetic stripe that is less than or equal to a predetermined threshold when read by a card reader (e.g., less than or equal to 100% of the ISO output specification). In the disclosed embodiments, high-output magnetic stripes can be used because the magnetic stripe is arranged within the card frame. High-output magnetic stripes are currently used in metal cards to overcome interference caused by the metallic material, which can lead to card reading failures.

[0059] like Figure 5A-5B As shown, the magnetic stripe 410 can be arranged within the card frame 405 at a distance D from the surface of the card frame 405. This surface can be the card insert 411. Figure 5A (as shown) or card housing 412 (e.g. Figure 5B The outer surface of the magnetic stripe 410 (as shown). Distance D represents the thickness of the material between the magnetic stripe 410 and the reader (e.g., the thickness of material the magnetic stripe 410 must pass through to "work" in order to output a signal). Distance D can be a function of material properties and manufacturing process constraints. In some embodiments, distance D can be in the range of 100-190 micrometers. Within this range, a high-output magnetic stripe can output a signal sufficient to allow the reader to capture the information encoded on the magnetic stripe. It should be understood that in some embodiments, distance D can be less than 100 micrometers or greater than 190 micrometers. From Figure 5A and 5B As can be understood, distance D also represents the distance from the bag 420 to the outer surface of the card insert 411 or card housing 412.

[0060] See Figure 6AWhen the pouch 420 is formed in the inner surface of the card housing 412, the magnetic stripe 410 can be arranged within the pouch 420 via another process. For example, before the card insert 411 and the card housing 412 are assembled together to form the card frame 405, the magnetic stripe 410 can be fixed to the inner surface of the card insert 411 (which does not have a pouch) via an adhesive layer (not shown). The magnetic stripe 410 can be adhered to the inner surface of the card insert 411 at a position corresponding to the position of the pouch 420 in the inner surface of the card housing 412, such that when the card insert 411 and the card housing 412 are attached to each other, the magnetic stripe 410 is aligned with the pouch 420.

[0061] Figure 6A The magnetic stripe 410 is schematically shown attached to the inner surface of the card insert 411, and is arranged within the pocket 420 when the card insert 411 is assembled with the card housing 412. Although the magnetic stripe 410 is shown not to occupy the entire space of the pocket 420, it should be understood that the magnetic stripe 410 may occupy the entire space of the pocket 420. In some embodiments, an adhesive layer may not be used. The magnetic stripe 410 may be placed within the pocket 420 and is securely held by the card insert 411 and the card housing 412 when the card insert and the card housing are attached to each other to form the card frame 405. It should be understood that when an adhesive layer is not used, the magnetic stripe 410 may occupy the entire space of the pocket 420 at least in the thickness direction of the card frame 405, such that the magnetic stripe 410 is constrained at least in the thickness direction.

[0062] Similarly, when the bag 420 is formed in the inner surface of the insert 411 by injection molding or machining, such as Figure 5A and 6B As shown, the magnetic stripe 410 can be arranged within the bag 420 via a suitable process similar to that described above. For example, in one process, after the bag 420 is formed in the insert 411, an adhesive layer (not shown) can be placed within the bag 420. The magnetic stripe 410 can be placed onto the adhesive layer and secured to the inner surface of the insert 411 by the adhesive layer, as shown. Figure 5A As shown. Then, the card insert 411 and the card housing 412 can be assembled together to form the card frame 405. Figure 5A The diagram schematically illustrates a magnetic stripe 410 positioned within a pocket 420 disposed in the inner surface of a card insert 411 when a card frame 405 is formed. In some embodiments, an adhesive layer may be omitted. The magnetic stripe 410 may be placed within the pocket 420 and securely held by the card insert 411 and the card housing 412 when the card insert and card housing are attached to each other to form the card frame 405. It should be understood that when an adhesive layer is not used, the magnetic stripe 410 may occupy at least the entire space of the pocket 420 in the thickness direction of the card frame 405, such that the magnetic stripe 410 is constrained at least in the thickness direction.

[0063] In another embodiment, such as Figure 6BAs shown, before the card insert 411 and the card housing 412 are assembled together, the magnetic stripe 410 can be adhered to the inner surface of the card housing 412 (which does not have a pocket) via an adhesive layer (not shown). The magnetic stripe 410 can be adhered to the inner surface of the card housing 412 at a position corresponding to the position of the pocket 420 on the inner surface of the card insert 411, such that when the card insert 411 and the card housing 412 are assembled, the magnetic stripe 410 is aligned with the pocket 420. Figure 6B The magnetic stripe 410 is schematically shown adhered to the inner surface of the card housing 412, and arranged within the pocket 420 when the card insert 411 is assembled with the card housing 412. Although the magnetic stripe 410 is shown not to occupy the entire space of the pocket 420, it should be understood that the magnetic stripe 410 may occupy the entire space of the pocket 420. In some embodiments, an adhesive layer may not be used. The magnetic stripe 410 may be placed within the pocket 420 and securely held by the card insert 411 and the card housing 412 when the card insert and the card housing are attached to each other to form the card frame 405. It should be understood that when an adhesive layer is not used, the magnetic stripe 410 may occupy at least the entire space of the pocket 420 in the thickness direction of the card frame 405, such that the magnetic stripe 410 is confined at least in the thickness direction.

[0064] Figure 7 Depicting along Figure 4 The line AA is intercepted Figure 4 The cross-sectional view of the exemplary transaction card 400 shown is consistent with various disclosed embodiments. (As...) Figure 7 As shown, the pouch 420 may include two parts: a first part formed in the inner surface of the card insert 411, and a second part formed in the inner surface of the card housing 412. For example, the inner surface of the card insert 411 may have a recessed portion defining the first part of the pouch 420, and the inner surface of the card housing 412 may have a corresponding recessed portion defining the second part of the pouch 420. A magnetic stripe 410 may be disposed within the pouch 420 formed in both the card insert 411 and the card housing 412. Although Figure 7 The illustration shows that the magnetic strip 410 does not occupy the entire space of the bag 420; however, it should be understood that in other embodiments, the magnetic strip 410 may occupy the entire space of the bag 420. For example... Figure 7As shown, the magnetic stripe 410 is secured to the inner surface of the card insert 411 via an adhesive layer (not shown). When the card insert 411 and the card housing 412 are assembled together, the magnetic stripe 410 is disposed within both the first and second portions of the pouch 420. It should be understood that in other embodiments, the magnetic stripe 410 may be secured to the inner surface of the card housing 412, and when the card insert 411 and the card housing 412 are assembled together, the magnetic stripe 410 is positioned within both the first and second portions of the pouch 420. In some embodiments, the adhesive layer may not be used. The magnetic stripe 410 may be placed within the first or second portion of the pouch 420 before the card insert 411 and the card housing 412 are assembled to form the card frame 405. When the card frame 405 is formed, the magnetic stripe 410 can be securely held by the card insert 411 and the card housing 412. It should be understood that when the adhesive layer is not used, the magnetic stripe 410 can occupy the entire space of the pouch 420 at least in the thickness direction of the card frame 405, so that the magnetic stripe 410 is restricted at least in the thickness direction.

[0065] Figure 8A and 8B Show along Figure 4 The line AA is intercepted Figure 4 The cross-sectional view of the exemplary transaction card 400 shown is consistent with various disclosed embodiments. (As...) Figure 8A and 8B As shown, the transaction card 400 may have a curved card frame. That is, the surface of the card frame 405 may be curved rather than flat. Figure 8A and 8B As shown, the magnetic strip 410 may also have a curved shape. For simplicity, Figure 8A and 8B The pouch 420 is not shown separately. It should be understood that the magnetic strip 410 may be arranged within the pouch 420, as in other embodiments disclosed herein. The magnetic strip 410 may occupy a portion or the entire space of the pouch 420. The curved magnetic strip 410 may follow the same curvature as the curved surface (or one of the curved surfaces) of the card frame 405. In some embodiments, the curved magnetic strip 410 may have a different curve than the curve of the card frame 405. Figure 8A and 8B As shown, the magnetic stripe 410 can be disposed on the inner surface of the card insert 411 or the card housing 412. As discussed above, the magnetic stripe 410 can be disposed within a pocket 420, which is disposed on the inner surface of the card insert 411, the card housing 412, or both. It should be understood that... Figure 8A and 8B The illustrated embodiments can be combined with other embodiments, such as... Figure 2-7 The embodiments shown.

[0066] Figure 9A and 9BA top view of an exemplary transaction card 400 consistent with the disclosed embodiments is shown. A magnetic stripe 410 is disposed within a card frame 405 and may be visible or invisible. For example, when the material used to form the card insert 411 and / or card housing 412 is opaque or translucent, the magnetic stripe 410 disposed within the card frame 405 is not visible from the outside. When the material forming the card insert 411 and / or card housing 412 is transparent or translucent, the magnetic stripe 410 is visible from the outside. When a transparent or translucent material is used to form a portion of the card insert 411 and / or card housing 412 at a location corresponding to the position of the magnetic stripe 410, the magnetic stripe 410 is visible from the outside.

[0067] In embodiments where the magnetic stripe 410 is not visible, a bar indicator 430 may be disposed on the outer surface (e.g., front or rear surface) of the card frame 405 to indicate to a user the position of the magnetic stripe 410 within the card frame 405. The bar indicator 430 may be disposed on the outer surface at the same location as the magnetic stripe 410 relative to the edge of the card frame 405. In other words, the bar indicator 430 may be located on the outer surface above the magnetic stripe 410 in the thickness dimension of the card frame 405. The bar indicator 430 may include various indicators for indicating the position of the magnetic stripe 410. For example, the bar indicator 430 may appear different from other portions of the outer surface of the card frame 405 to indicate the position of the magnetic stripe 410. In one embodiment, the bar indicator 430 may have a different color than other portions of the outer surface. In another embodiment, the bar indicator 430 may have a printed pattern not present in other portions of the outer surface. In some embodiments, the bar indicator 430 may include a material that feels or appears different from the material contained in other portions of the card frame 405. In some embodiments, the bar indicator 430 may use icons, text or other suitable decorative items to indicate the position of the magnetic bar 410.

[0068] Other aesthetic techniques known in the art can also be used in the bar indicator 430 to indicate the position of the magnetic stripe 410 within the card frame 405. For example, the bar indicator 430 can be printed with ink having a different finish than other portions of the outer surface of the card frame 405. In one embodiment, the bar indicator 430 can be printed with a textured finish, while other portions of the outer surface can be printed with a gloss finish. Other aesthetic techniques, such as thermal conversion (e.g., the bar indicator 430 having a different heat transfer capability than other portions of the card frame 405), can also be used to indicate the position of the internal magnetic stripe 410. It should be understood that... Figure 9A and 9B The embodiments shown can be combined with other embodiments disclosed herein, such as... Figure 2 -8 The embodiments disclosed.

[0069] Different materials can be used to construct the card frame 405, which includes the card insert 411 and the card housing 412. Suitable materials include TPE (thermoplastic elastomer) resins and blends of TPE with another material, such as TPE-PBT resin (a thermoplastic elastomer blended with polybutylene terephthalate), TPE blended with acetal polymers, etc. Acetal polymers may include commercially available acetal polymers, such as those derived from... Manufactured If necessary, other or different commercially available homopolymers may be used.

[0070] Thermoplastic elastomers (TPEs) may include copolymers and / or mixtures of polymers exhibiting thermoplastic and elastic material properties. For example, the resin used to form the card frame 405 may include polyester elastomers, block copolymers, thermoplastic olefins, elastic alloys, cushion-plastic polyurethanes, thermoplastic copolyesters, or thermoplastic polyamides.

[0071] In some embodiments, the resin mixture used to form the card frame 405 includes a polyester elastomer, such as a commercially available polyester elastomer. Commercially available polyester elastomers suitable for forming the card frame 405 with a soft touch may include those made of… Manufactured 8238. Other commercially available suitable polyester elastomers may include those made from... Manufactured 7246. Although some commercially available TPEs have been specifically mentioned herein, other TPEs may be used in the various embodiments.

[0072] The resin mixture used to form the card frame 405 may include materials for increasing the strength and durability of the card frame 405. For example, the resin mixture used to form the card frame 405 may include polybutylene terephthalate (PBT) or a mixture thereof with materials comprising PBT. Suitable PBT or materials comprising PBT may include commercially available PBT, such as PBT derived from... Manufactured If necessary, other or different commercially available PBT or materials containing PBT may be used. As used herein, PBT should be understood to include materials containing PBT.

[0073] The PBT used in the resin mixture forming the card frame 405 may have a flexural modulus in the range of 1600-8500 MPa. For example, the PBT used in the resin mixture forming the card frame 405 may have a flexural modulus in the range of 1600-8500 MPa, 2000-8000 MPa, 2500-7500 MPa, 3000-7000 MPa, 3500-6500 MPa, 4000-6000 MPa, 4500-5500 MPa, or 4750-5250 MPa. Depending on the PBT and / or other materials selected in the resin forming the card frame 405, the selected PBT may have different flexural moduli if necessary.

[0074] The PBT used in the resin mixture forming the card frame 405 may also have a flexural modulus in the range of 50-200 MPa. For example, the PBT used for the card frame 405 may have a flexural modulus in the range of 50-200 MPa, 75-175 MPa, 100-150 MPa, or 120-130 MPa. Depending on the PBT and / or other materials selected in the resin forming the card frame 405, the selected PBT may have different flexural moduli if necessary.

[0075] The resin mixture used to form the card frame 405 may include a mixture of TPE and one or more of acetal polymers and PBT. The resin mixture for forming the card frame 405 may include a mixture having a 50:50, 60:40, 40:60, 70:30, 30:70, or other ratio of TPE to one or more of acetal polymers and PBT. If necessary, the resin mixture used to form the card frame 405 may include other or additional materials.

[0076] Consistent with the disclosed embodiments, a high-output magnetic stripe can be used as the internal magnetic stripe 410 to reduce the failure rate and meet ISO standards. For example, the failure rate of the high-output internal magnetic stripe 410, consistent with the disclosed embodiments, will not exceed 1.5%, 2%, or 3%. Magnetic stripes used in conventional cards will not meet ISO standards for card read failure rates because they are typically low-output magnetic stripes.

[0077] Figure 10 This is a flowchart illustrating an exemplary method 1000 for manufacturing a transaction card, consistent with the disclosed embodiments. Method 1000 can be performed by one or more machines or devices, such as injection molding equipment, CNC machining equipment, and other automated manufacturing equipment, which can be controlled by at least one processor. The processor can be specifically programmed to operate one or more manufacturing devices to perform the disclosed method for manufacturing transaction card 400.

[0078] like Figure 10As shown, method 1000 may include forming a card insert (step 1005). For example, an injection molding apparatus may form a card insert 411. Method 1000 may also include forming a card housing (step 1010). For example, an injection molding apparatus may form a card housing 412.

[0079] Method 1000 may include forming a bag in at least one of a card insert or a card housing (step 1015). For example, an injection molding apparatus may form the bag 420 in the inner surface of the card insert 411, the inner surface of the card housing 412, or both (by forming a first portion of the bag 420 in the inner surface of the card insert 411 and a second portion of the bag 420 in the inner surface of the card housing 412). When the bag 420 is formed in the card insert 411 or the card housing 412, the bag 420 may be formed in the same injection molding process as the card insert 411 or the card housing 41. When the bag 420 is formed by the first portion in the card insert 411 and the second portion in the card housing 412, the first portion may be formed together with the card insert 411 in the same injection molding process. The second portion may be formed together with the card housing 412 in the same injection molding process. In some embodiments, after the insert 411 and / or the housing 412 are formed, a subsequent CNC machining operation may form a pocket 420 in the inner surface of the insert 411, the housing 412, or both. The pocket 420 may be formed in the inner surface of the insert 411 and / or the housing 412 by removing a portion of the insert 411 and / or the housing 412 from the inner surface of the insert and the housing.

[0080] Method 1000 may include positioning a magnetic stripe on at least one of the inner surfaces of a card insert or a card housing (step 1020). For example, the magnetic stripe 410 may be secured (e.g., via an adhesive layer) to the inner surface of the card insert 411 or the inner surface of the card housing 412 at a location corresponding to the position of the pocket 420. In some embodiments, an adhesive layer may not be used. The magnetic stripe 410 may be disposed within the pocket 420 and securely held by the card insert 411 and the card housing 412 when they are attached to each other.

[0081] Method 1000 may further include attaching a card insert to a card housing to form a card frame (step 1025). When the card frame is formed, a magnetic stripe is disposed within the card frame between the card insert and the card housing.

[0082] In some embodiments, the method may further include forming another pocket in the card insert 411 and / or card housing 412 to embed the microchip. In some embodiments, the method may further include printing card signals on the surface of the card insert and / or card housing. Card signals may include, but are not limited to, card digits, card expiration date, VISA / MasterCard logo, hologram, issuing company logo, consumer / cardholder name, cardholder photograph, and cardholder signature. Although illustrative embodiments are described herein, the scope includes any and all embodiments, adaptations, or modifications having equivalent elements, modifications, omissions, combinations (of aspects of the embodiments) based on this disclosure. For example, the order of steps in the exemplary methods described above may be rearranged in any preferred or suitable order, or any step may be removed or added. Elements in the claims are intended to be interpreted broadly based on the language used in the claims, and not limited to the examples described in this specification or during the examination of this application, which should be understood as non-exclusive. Therefore, the specification and examples are intended to be understood as merely illustrative, and the true scope and spirit are represented by the full scope of the following claims and their equivalents.

[0083] Cross-reference to related applications

[0084] This application claims priority to U.S. Provisional Patent Application Serial No. 62 / 385,220, filed September 8, 2016, the contents of which are incorporated herein by reference in their entirety.

Claims

1. A transaction card, comprising: Card frame, comprising a card insert and a card housing; A pouch is formed in at least one of the card insert or card housing; Magnetic strip, placed inside the bag. In this embodiment, at least a portion of the magnetic stripe covering the card insert or card housing is formed of a transparent material.

2. The transaction card according to claim 1, wherein, The magnetic strip occupies the entire space of the bag so that the magnetic strip is constrained at least in the thickness direction.

3. The transaction card according to claim 1, wherein, The magnetic strip is a high-output magnetic strip.

4. The transaction card according to claim 1, wherein, It also includes an adhesive layer arranged inside the bag, through which the magnetic stripe is secured to the card frame.

5. The transaction card according to claim 1, wherein, The magnetic stripe is located at a distance of 100-190 micrometers from the outer surface of the card insert or card housing.

6. The transaction card according to claim 1, wherein, The card frame has a first curved shape, and wherein, The magnetic strip has a second curved shape.

7. The transaction card of claim 1, further comprising a bar indicator located on the outer surface of the card frame.

8. The transaction card according to claim 7, wherein, The bar indicator includes an icon or text indicating the position of the magnetic bar.

9. The transaction card according to claim 7, wherein, The bar indicator may be a color different from the color of the outer surface of the card frame, a texture different from the texture of the outer surface of the card frame, or a printed pattern not presented on the outer surface of the card frame.

10. The transaction card according to claim 7, wherein, The bar indicator is located at the same position as the magnetic stripe on the edge of the card frame.

11. The transaction card according to claim 1, wherein, The card insert includes a first recessed portion, the card housing includes a second recessed portion, and the first and second recessed portions together form a pocket.

12. A method for manufacturing a transaction card, comprising: A card frame is formed, the card frame including a card insert and a card housing, wherein at least a portion of the card insert or the card housing is formed of a transparent material; Forming a bag within a frame; forming a bag within a card frame; Position the magnetic strip inside the bag; and The card insert is attached to the card housing to capture the magnetic stripe inside the bag, wherein, after the card insert is attached to the card housing, the magnetic stripe is covered by the portion of the card insert or card housing formed of a transparent material.

13. The method according to claim 12, wherein, The positioning magnetic strip includes a positioning magnetic strip to occupy the entire space of the bag so that the magnetic strip is constrained in at least the thickness direction.

14. The method according to claim 12, wherein, Positioning magnetic strips include high-output positioning magnetic strips.

15. The method of claim 12, further comprising: The adhesive layer is placed inside the bag; as well as The magnetic stripe is secured to the card frame using an adhesive layer.

16. The method of claim 12, further comprising positioning the magnetic stripe at a distance of 100-190 micrometers from the outer surface of the card insert or the card housing.

17. The method according to claim 12, wherein: Forming the card frame includes forming a card frame having a first curved shape; and The positioning magnetic strip includes a positioning magnetic strip having a second curved shape.

18. The method of claim 12, further comprising forming a bar indicator disposed on the outer surface of the card frame.

19. The method according to claim 18, wherein, The bar indicator includes forming a bar indicator that includes icons or text indicating the position of the magnetic bar.

20. The method according to claim 18, wherein, Forming a bar indicator includes forming a bar indicator having at least one of the following: having a color different from the color of the outer surface of the card frame, having a texture different from the texture of the outer surface of the card frame, or having a printed pattern not presented on the outer surface of the card frame.

21. The method according to claim 18, wherein, The bar indicator is formed at the same location as the magnetic stripe about the edge of the card frame.

22. The method according to claim 12, wherein, A first recessed portion is formed in the insert; A second recessed portion is formed in the card housing, and the first and second recessed portions form a pocket.

Images