An internal insert and magnetic isolation based special-shaped metal intelligent card

Abstract

This invention discloses an irregularly shaped metal smart card based on internal inserts and magnetic shielding, relating to the field of smart cards. It includes a metal substrate, a dual-interface antenna and chip module, and a double-sided composite magnetic shielding layer. By adopting an integrally molded metal frame, stress concentration points and seam defects in the process are eliminated. Through a three-in-one architecture of continuous metal frame, internal functional cavity inserts, and double-sided overall magnetic shielding, functional cavities are precisely machined in the non-edge area of ​​the metal substrate, and the antenna module is placed as an internal insert, avoiding the metal frame. The double-sided composite magnetic shielding layer covers the entire area of ​​the metal substrate. A closed magnetic circuit with low magnetic resistance is constructed by using high magnetic permeability materials through the upper and lower magnetic shielding layers, which actively guides the magnetic lines of force of the reader to pass through the antenna coil, rather than being reflected or consumed by the metal, thus suppressing the eddy current loss of the metal substrate.

Description

Technical Field

[0001] This invention relates to the field of smart cards, and in particular to an irregularly shaped metal smart card based on internal inserts and magnetic shielding. Background Technology

[0002] Metal smart cards are favored for their excellent texture, durability and security; however, the shielding effect of metal materials on electromagnetic waves seriously hinders contactless communication functions.

[0003] In order to solve the signal shielding problem, existing metal smart cards commonly use slotted antennas or hollowed-out frame solutions. This involves cutting slots or windows into the metal card body to place the antenna. However, the wide slots disrupt the continuity of the metal frame, resulting in a significant decrease in the card's structural strength. This leads to stress concentration points, poor resistance to bending and torsion, and obvious seams or boundaries in appearance, affecting aesthetics and feel.

[0004] Furthermore, the frame structure is made of metal and plastic, with the antenna embedded in the plastic. This method has a bonding interface between different materials, which is prone to delamination after long-term use, resulting in insufficient durability and inconsistent side texture.

[0005] Some solutions only use magnetic shielding materials locally at the bottom of the module, which is insufficient for guiding and optimizing the magnetic field. There is still room for improvement in contactless communication performance in a metal environment. Metal has high conductivity. When the smart card adopts an all-metal structure, the 13.56MHz alternating magnetic field generated by the reader will induce a severe eddy current effect on the metal surface, causing the magnetic field energy to be absorbed, reflected or canceled.

[0006] This application provides an irregularly shaped metal smart card based on internal embedding and magnetic shielding. It adopts an external integral embedding and magnetic shielding waveguide design. By designing an irregularly shaped metal frame with a continuous and uninterrupted outer edge, it ensures extreme robustness and high-end texture. At the same time, functional cavities are precisely machined in the non-edge area inside the frame to embed the antenna and chip as embedded components. Magnetic shielding sheets are covered on both sides of the metal substrate to guide the magnetic field, thereby solving the problem of metal shielding wireless signals and achieving a balance between structural strength and communication performance. Summary of the Invention

[0007] The purpose of this invention is to provide an irregularly shaped metal smart card based on internal inserts and magnetic shielding, so as to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: an irregularly shaped metal smart card based on internal inserts and magnetic shielding, wherein the metal smart card has a multi-layer composite structure, comprising: The metal substrate is an irregularly shaped continuous metal substrate with an outer edge that is a continuous, seamless, one-piece molded metal frame. At least one through or semi-through functional cavity is provided in the non-edge area of ​​the metal substrate. The dual-interface antenna and chip module is an internal functional insert that integrates the dual-interface chip module and an independent antenna module of FPC flexible antenna or wire-wound coil antenna. The antenna module is fixedly housed in the functional cavity in the form of an insert, and the antenna coil plane is arranged parallel to the surface of the metal substrate. The double-sided composite magnetic shielding layer uses a flexible magnetic shielding material with high magnetic permeability to completely adhere to and cover the upper and lower outer surfaces of the metal substrate, fully covering and filling the functional cavity area, so as to construct a symmetrical low magnetic reluctance closed magnetic circuit between the metal substrate and the outside, which is used to construct a closed magnetic circuit and suppress eddy current loss.

[0009] Preferably, the antenna module is a standardized independent module, which is fixed in the functional cavity by adhesive or mechanical clips. After fixing, the outer surface of the antenna module is flush with the outer surface of the metal substrate.

[0010] Preferably, the antenna module is a pre-integrated and functionally tested independent standardized module.

[0011] Preferably, the functional cavity is manufactured by CNC precision carving or chemical etching, and the cavity edge is chamfered.

[0012] Preferably, the outline shape of the irregular continuous metal frame includes a rectangle, a circle, a streamline, or a customized irregular outline, and the metal substrate is manufactured by a one-piece molding process with no stress concentration points.

[0013] Preferably, the double-sided composite magnetic shielding layer is divided into an upper magnetic shielding layer and a lower magnetic shielding layer. Both the upper and lower magnetic shielding layers are made of flexible magnetic shielding material with high magnetic permeability, and the shapes of the upper and lower magnetic shielding layers are completely matched with the outer contour of the metal substrate.

[0014] Preferably, the upper and lower magnetic shielding layers are symmetrically arranged on the upper and lower surfaces of the metal substrate and are tightly bonded to the upper and lower outer surfaces of the metal substrate, respectively. The upper and lower magnetic shielding layers completely cover the filling functional cavity area, which is used to construct a symmetrical low magnetic resistance path between the reader and the metal substrate, so that the reading and writing performance of the card is consistent on both sides.

[0015] Preferably, it also includes an external decorative and protective layer, which is divided into an upper protective layer and a lower protective layer. It is made of wear-resistant transparent materials such as PET, PC or PVC, and is superimposed with a printing layer, ink layer or leather or wood decorative layer. The external decorative and protective layer is hot-pressed onto the outside of the upper and lower magnetic shielding layers to form a waterproof and dustproof sealed structure.

[0016] Preferably, the upper and lower magnetic shielding layers form a structural filler in the functional cavity area, making the upper and lower surfaces of the composite card flat, providing a flat bonding base for the upper and lower protective layers.

[0017] Preferably, the functional cavity is formed by removing local material without disrupting the continuity of the metal frame.

[0018] The technical effects and advantages of this invention are as follows: 1. By adopting a continuous, seamless, one-piece molded metal frame, stress concentration points and seam defects of traditional splicing processes are eliminated. The metal substrate serves as the main skeleton, improving its resistance to bending and torsion, and effectively eliminating the risk of fatigue fracture that is prone to occur at gaps during long-term use. At the same time, it supports arbitrary irregular contour designs, realizing an all-metal integrated appearance.

[0019] 2. Through a three-in-one architecture of continuous metal frame, internal functional cavity insert, and double-sided overall magnetic shielding, the functional cavity is precisely machined in the non-edge area of ​​the metal substrate, and the antenna module is placed as an internal insert, avoiding the metal frame. This design preserves the continuity and strength of the metal frame, while providing a safe electromagnetic island for the antenna. It breaks free from the constraints of antenna layout on appearance design, reconstructs the design paradigm of metal smart cards at the system level, and achieves the unity of structural support, functional integration and environmental shielding.

[0020] 3. A double-sided composite magnetic shielding layer is used to fully cover the metal substrate. A closed magnetic circuit with low magnetic resistance is constructed by using high magnetic permeability materials through the upper and lower magnetic shielding layers. This actively guides the magnetic lines of force of the reader to pass through the antenna coil, rather than being reflected or consumed by the metal. This suppresses the eddy current loss of the metal substrate, improves the coupling efficiency of the radio frequency signal and the stability of the read and write distance, ensures consistent read and write performance on both sides, and guarantees the superior stability of communication and a longer read and write distance.

[0021] 4. By completely decoupling the antenna module from the metal casing at the physical and electromagnetic levels, the appearance of the metal substrate is no longer rigidly limited by the antenna layout. Whether it is a complex streamline, a very small rounded corner radius, or an irregular artistic shape, it will not affect the RF performance. The antenna and chip are pre-integrated into independent, 100% tested modules. During the assembly stage, only qualified modules are installed as inserts into the metal substrate, avoiding the scrapping of the entire card due to antenna or chip defects.

[0022] 5. The magnetic shielding layer not only guides the magnetic circuit but also fills the height difference of the functional cavity, providing a flat bonding surface for the upper and lower protective layers. Combined with the vacuum lamination process, it ensures the overall flatness, thickness uniformity, and interlayer bonding strength of the card, and has excellent protective properties such as waterproof, dustproof, wear-resistant, and corrosion-resistant. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the metal substrate structure of the present invention; Figure 3 This is a schematic diagram of the antenna module structure of the present invention; Figure 4 This is a front view of the antenna module of the present invention; Figure 5 This is a schematic diagram of the reverse side of the antenna module of the present invention.

[0024] In the figure: 1. Metal substrate; 11. Functional cavity; 2. Antenna module; 3. Double-sided composite magnetic shielding layer. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] This invention provides, for example Figures 1-5 The diagram shows an irregularly shaped metal smart card based on internal inserts and magnetic shielding. The metal smart card has a multi-layer composite structure, which consists of, from top to bottom: an upper protective layer, an upper magnetic shielding layer, a metal substrate 1 and internal functional inserts, a lower magnetic shielding layer, and a lower protective layer. The metal substrate 1, as the main skeleton of the card, is manufactured using a one-piece molding process. Its outer edge is a continuous, seamless, one-piece molded metal frame. This frame can be designed as a rectangle, a circle, a streamline, or any custom irregular shape. It eliminates the stress concentration points of traditional splicing processes, improves bending and torsion resistance, avoids the risk of fatigue fracture, and is not limited by antenna layout. Achieving ultimate mechanical strength, durability, and a complete metallic appearance, the irregularly shaped continuous metal substrate 1 serves as the main load-bearing skeleton and structural support of the card. It is manufactured using a one-piece molding process, eliminating stress concentration points and improving bending and torsion resistance, thus avoiding the risk of fatigue fracture. The outer edge of the metal substrate 1 is a fully integrated metal side without any seams, boundaries, or gaps. It offers high design freedom, supporting any irregular shape design and is not limited by antenna layout.

[0027] In the non-edge area of ​​the metal substrate 1, one or more through grooves or cavities are formed by precision machining, called functional cavities 11. These functional cavities 11 remove only local material without disrupting the continuity of the metal frame of the metal substrate 1. Specifically, at least one through or semi-through functional cavity 11 can be formed by CNC precision carving or etching. The cavity tolerance is controlled within ±0.05mm, and the edge chamfer is R0.1-R0.3 to ensure no sharp burrs. The cavity does not disrupt the continuity of the outer edge frame at all.

[0028] The dual-interface antenna and chip module, which is an internal functional insert, integrates a dual-interface smart card chip module that supports ISO7816 and ISO14443 standards, an FPC flexible antenna or a wound coil antenna into an independent antenna module 2. The antenna module 2 can only be put into use after 100% functional testing. The antenna module 2, as a complete insert, is precisely housed in the functional cavity 11 of the metal substrate 1. The antenna coil plane is arranged parallel to the outer surface of the metal substrate 1.

[0029] The antenna module 2 is fixed in the functional cavity 11 by adhesive or mechanical clips. The width and length of the antenna module 2 are smaller than the inner diameter of the metal frame 1. Specifically disclosed, the internal functional insert is placed inside the metal functional cavity 11. The internal functional insert includes a dual-sided antenna and a chip module electrically connected to the antenna. The chip module can be a dual-interface module that supports both contact and contactless communication, or it can be a purely contactless module.

[0030] The dual-interface antenna and chip module serve as the core functional units and wireless communication interface of the card, enabling data processing and energy transmission. The dual-interface antenna and chip module are produced in a modular manner, and the antenna module 2 is pre-tested, so the yield rate is controllable and the scrap of the whole card is avoided. The antenna module 2 is installed as an insert, which facilitates automated mass production. It cooperates with the functional cavity 11 on the metal substrate 1 and has high positioning accuracy. The faulty module can be replaced individually. The FPC flexible antenna or the wire-wound coil antenna is pre-integrated as an independent antenna module 2 and decoupled from the metal. The antenna performance is not affected by the shape of the metal shell and the consistency is improved.

[0031] The double-sided composite magnetic shielding layer 3 is made of a flexible magnetic shielding material with high magnetic permeability and low loss, and is completely attached to and covers the upper and lower outer surfaces of the metal substrate 1.

[0032] The double-sided composite magnetic shielding layer consists of an upper magnetic shielding layer and a lower magnetic shielding layer. Upper magnetic shielding layer: It adopts a flexible nanocrystalline or ferrite magnetic shielding material with high magnetic permeability and low loss. Its shape is completely matched with the outer contour of the metal substrate 1. It is tightly attached to the entire upper surface of the metal substrate 1, which not only completely covers the functional cavity 11 area, but also fills the height difference and provides a flat bonding base. The upper magnetic shielding layer actively collects and guides the alternating magnetic field generated by the reader into the card by constructing a low magnetic resistance path in the upper half, thereby reducing the eddy current loss of the metal substrate 1. The scattered magnetic lines of force are concentrated and guided to the antenna area, improving coupling efficiency and enabling active magnetic circuit guidance; the eddy current loss generated by the metal substrate 1 is reduced, thus suppressing eddy currents; the height difference of the functional cavity 11 is filled by the upper magnetic shielding layer, providing a flat bonding surface for the upper layer and achieving structural filling; the upper magnetic shielding layer protects the antenna module 2 from external force damage, thus providing physical protection. Lower magnetic shielding layer: It uses the same high magnetic permeability material as the upper magnetic shielding layer, and its shape is completely matched with the outer contour of the metal substrate 1, and it is tightly attached to and covers the entire lower surface of the metal substrate 1. The lower magnetic shielding layer constructs a low magnetic resistance path in the lower half, guiding the magnetic lines of force to complete a closed loop and return to the reader; The lower and upper magnetic shielding layers work together to form a complete three-dimensional magnetic circuit, realizing a complete cycle of magnetic field entry, coupling, and exit, achieving a complete magnetic circuit closure. The symmetrical magnetic shielding design of the upper and lower magnetic shielding layers ensures consistent read / write performance on both sides of the card, achieving a symmetrical magnetic field distribution. The double-sided shielding of the upper and lower magnetic shielding layers further suppresses the bidirectional eddy current loss of the metal substrate 1. The lower magnetic shielding layer performs a planarization process for the lower layer, providing a flat base surface for the lower layer. The double-sided composite magnetic shielding layer 3 establishes a defined low magnetic resistance path between the metal substrate 1 and the external reader / writer. When the alternating magnetic field generated by the reader / writer reaches the card, most of the magnetic lines of force are guided through the upper and lower magnetic shielding layers to form a loop, thereby bypassing the highly conductive metal layer, reducing eddy current loss, and at the same time serving as a protective layer and structural filler for the antenna module 2. The external decorative and protective layer consists of an upper protective layer and a lower protective layer, made of wear-resistant transparent materials such as PET, PC, or PVC. A printing layer, ink layer, or decorative layer of leather and wood can be superimposed as needed, and hot-pressed onto the outside of the magnetic shielding layer; it provides a carrier for brand logos and personalized patterns; achieves surface wear resistance, scratch resistance, and chemical corrosion resistance; and provides waterproof and dustproof sealing protection. The key manufacturing process steps are: S1: Metal substrate processing: Stamping, CNC precision carving or MIM of metal sheets to form a substrate with a specific irregular contour and internal functional cavity 11. The structure forms the main body and the insert mounting position, with high cavity precision to ensure the insert is installed in place; the edges are smooth and burr-free to avoid damaging the antenna; the processing stress is low and the material deformation is controllable; suitable for mass production. S2: Antenna module fabrication: A coil antenna is fabricated on a flexible substrate, and a dual-interface chip is bonded using COB or packaging processes to complete module testing.

[0033] It serves as the core unit for manufacturing functionally qualified components, undergoes pre-testing to avoid waste in subsequent processes; chip bonding quality is controllable; antenna parameters have good consistency; and the modules are standardized and interchangeable. S3: Insert assembly: The qualified antenna module 2 is precisely installed into the functional cavity 11 of the metal substrate 1 by means of low-gas release adhesive or mechanical snap-fit. After fixing, the outer surface of the antenna module 2 is flush with the outer surface of the metal substrate 1 or within the same tolerance zone. It achieves integration of functional units and the main structure, with high positioning accuracy and good antenna position consistency; high bonding strength, impact and vibration resistance; low gas release material to avoid air bubbles in subsequent lamination; good flatness to ensure the bonding quality of the magnetic shielding layer; S4: Double-sided magnetic shielding layer bonding: The pre-cut magnetic shielding sheet is precisely aligned and bonded to the upper and lower surfaces of the metal substrate 1, completely covering the functional cavity 11 area. A complete magnetic circuit optimization system is constructed, ensuring high alignment accuracy and complete coverage without deviation; the rolling process ensures tight bonding without air gaps; the absence of air bubbles prevents magnetic circuit interruption; and double-sided synchronous bonding ensures symmetrical stress. S5: Overall lamination packaging: Lamination, printing, film coating and other subsequent processes are performed on the outside of the magnetic shielding layer to complete the final product; Achieves integrated packaging with multi-layer structure; vacuum environment avoids interlayer bubbles; precise temperature and pressure control ensures high bonding strength; each layer is tightly bonded, eliminating the risk of delamination; card has good overall flatness and uniform thickness.

[0034] The system's working principle and signal transmission mechanism are as follows: Magnetic field path establishment: When the alternating magnetic field generated by the reader antenna reaches the card surface, it is collected by the high permeability upper magnetic shielding layer; Magnetic field line guidance: Magnetic field lines are guided through the upper magnetic shielding layer and into the internal space of the card. Since the metal substrate 1 is continuous and covered by the magnetic shielding layer, the eddy currents generated therefrom are suppressed. Energy coupling: The magnetic lines of force guided to the inside pass through the built-in antenna coil, generating an induced current in the coil according to the law of electromagnetic induction, thereby powering the chip and establishing a communication link; Loop closure: The magnetic field lines continue downward, pass through the lower magnetic shielding layer, and return to the reader, forming a complete and efficient closed magnetic circuit.

[0035] This mechanism ensures that communication energy is coupled to the built-in antenna to the maximum extent, rather than being consumed or reflected by the metal layer.

[0036] Complete working principle and signal transmission process: The working principle adopts a main magnetic field guidance mechanism, which is completely different from the traditional electric field coupling or slot radiation method. The specific working process is divided into five consecutive steps: Step 1: Magnetic field emission and collection When the smart card is brought close to the reader, the reader antenna generates an alternating magnetic field of 13.56MHz according to the ISO14443 standard. When this magnetic field reaches the card surface, most of the magnetic lines of force will be actively collected and concentrated by the upper magnetic shielding layer because the upper magnetic shielding layer has a much higher permeability than air and metal, rather than being reflected or consumed by the metal substrate 1. This solves the problem of magnetic field reflection on the metal surface and improves the utilization rate of the magnetic field. Step 2: Magnetic lines of force are guided into the interior. The collected magnetic field lines are conducted into the card through the low magnetic resistance path of the upper magnetic shielding layer. Since the entire upper surface of the metal substrate 1 is covered by the magnetic shielding layer, the eddy current effect generated on the metal surface is suppressed, and the magnetic field lines can smoothly penetrate into the functional cavity 11 region, solving the problem of metal eddy current loss and reducing energy loss. Step 3: Antenna energy coupling The magnetic field lines guided to the functional cavity 11 region pass perpendicularly through the built-in antenna coil. According to the law of electromagnetic induction, the changing magnetic field generates an induced electromotive force in the coil, which in turn generates an induced current. This current provides the chip with operating power and carries the data signal sent by the reader, achieving efficient energy and signal coupling and stable read / write distance. Step 4: Magnetic circuit conducts downwards After passing through the antenna coil, the magnetic field lines continue to conduct downwards into the lower magnetic shielding layer. The lower magnetic shielding layer also provides a low magnetic resistance path, guiding the magnetic field lines to conduct downwards into the card, ensuring the continuity of the magnetic circuit and preventing the magnetic field lines from dissipating inside the metal. Step 5: Loop Closure and Data Return After passing through the lower magnetic shielding layer, the magnetic field lines leave the card and return to the reader antenna, forming a complete and efficient closed magnetic circuit. At the same time, the chip modulates the antenna load impedance to transmit the response data back to the reader through the same magnetic circuit, completing bidirectional communication and forming a complete energy and information closed loop, achieving stable and reliable full-duplex communication.

[0037] Example 1: Key manufacturing processes, specifically: S1: Metal substrate processing: Stainless steel, titanium alloy or aluminum alloy sheet is used. The outer contour is formed by stamping and blanking. Then, the functional cavity 11 is processed in the non-edge area by CNC five-axis precision carving or chemical etching process. The cavity tolerance is controlled within ±0.05mm. The edge chamfer is R0.1-R0.3 to ensure that the edge is smooth and burr-free, so as to avoid subsequent damage to the antenna. S2: Antenna module fabrication: Antenna coils are fabricated on FPC substrates using etching processes, smart card chips are soldered using COB bonding processes, 100% electrical performance and communication function tests are conducted, and qualified modules are screened. S3: Insert assembly: Apply low-release epoxy resin adhesive in the functional cavity 11, and place the antenna module 2 into the cavity with an accuracy of ±0.02mm using a visual positioning system. Pressurize and cure to ensure that the module is firmly bonded to the metal substrate 1 and the flatness is ≤0.03mm, providing a reference for subsequent magnetic shielding layer bonding. S4: Double-sided magnetic shielding layer bonding: The pre-cut magnetic shielding sheet is bonded to the upper and lower surfaces of the metal substrate 1 respectively through a precision alignment bonding equipment. A roller bonding process is adopted, and the pressure is controlled at 5-8 kgf / cm² to ensure no bubbles, no warping, and 100% tight bonding, eliminating the risk of magnetic circuit interruption. S5: Overall lamination and packaging: The lower protective layer, lower magnetic shielding layer, metal substrate 1 assembly, upper magnetic shielding layer, upper protective layer, and printed layer are stacked in sequence and sent into a vacuum hot press. The temperature is set to 120-140℃, the pressure to 10-15kgf / cm², the vacuum degree to ≤1mbar, and the pressure is maintained for 20-30 minutes to complete the overall lamination. Post-processing and final inspection include punching the shape, milling grooves, marking, and personalized printing. Finally, full-function testing and appearance inspection are carried out to ensure 100% functional qualification; and full inspection of appearance defects is conducted to improve the consistency of finished products.

[0038] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A non-circular metal smart card based on internal inserts and magnetic shielding, characterized in that, The metal smart card has a multi-layered composite structure, including: The metal substrate (1) is an irregular continuous metal substrate with an outer edge that is a continuous, seamless, integrally formed metal frame. At least one through or semi-through functional cavity (11) is provided in the non-edge area of ​​the metal substrate (1). The dual-interface antenna and chip module is an internal functional insert. The internal functional insert integrates the dual-interface chip module and the independent antenna module (2) of the FPC flexible antenna or the wound coil antenna. The antenna module (2) is fixedly housed in the functional cavity (11) in the form of an insert, and the antenna coil plane is arranged parallel to the surface of the metal substrate (1). The double-sided composite magnetic shielding layer (3) is made of a flexible magnetic shielding material with high magnetic permeability. It is completely attached to the upper and lower outer surfaces of the metal substrate (1) and completely covers the area of ​​the filling functional cavity (11) to build a closed magnetic circuit with low magnetic resistance between the metal substrate (1) and the outside, which is used to build a closed magnetic circuit and suppress eddy current loss.

2. The irregularly shaped metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The antenna module (2) is a standardized independent module. The antenna module (2) is fixed in the functional cavity (11) by adhesive or mechanical snap-fit. After fixing, the outer surface of the antenna module (2) is flush with the outer surface of the metal substrate (1).

3. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 2, characterized in that, The antenna module (2) is a pre-integrated and functionally tested independent standardized module.

4. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The functional cavity (11) is processed by CNC precision carving or chemical etching process, and the edge of the cavity is chamfered.

5. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The outline shape of the irregular continuous metal frame includes rectangular, circular, streamlined or customized irregular outline, and the metal substrate (1) is manufactured by a one-piece molding process without stress concentration points.

6. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The double-sided composite magnetic shielding layer (3) is divided into an upper magnetic shielding layer and a lower magnetic shielding layer. Both the upper and lower magnetic shielding layers are made of flexible magnetic shielding material with high magnetic permeability. The shapes of the upper and lower magnetic shielding layers are completely matched with the outer contour of the metal substrate (1).

7. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The upper and lower magnetic shielding layers are symmetrically arranged on the upper and lower surfaces of the metal substrate (1) and are tightly attached to the upper and lower outer surfaces of the metal substrate (1) respectively. The upper and lower magnetic shielding layers completely cover the filling cavity (11) area, which is used to construct a symmetrical low magnetic resistance path between the reader and the metal substrate (1) so that the reading and writing performance of the card is consistent on both sides.

8. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, It also includes an external decorative and protective layer, which consists of an upper protective layer and a lower protective layer. It is made of wear-resistant and transparent materials such as PET, PC or PVC, and is superimposed with a printing layer, ink layer or leather or wood decorative layer. The external decorative and protective layer is hot-pressed onto the outside of the upper and lower magnetic shielding layers to form a waterproof and dustproof sealed structure.

9. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 8, characterized in that, The upper and lower magnetic shielding layers form a structural filling in the functional cavity (11) region, making the upper and lower surfaces of the composite card flat, providing a flat bonding base for the upper and lower protective layers.

10. A non-circular metal smart card based on internal inserts and magnetic shielding according to claim 1, characterized in that, The functional cavity (11) is formed by removing local material without disrupting the continuity of the metal frame.

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