Method for manufacturing a metal transaction card and metal transaction card thus obtained

Abstract

The present invention relates to a method for manufacturing a metal transaction card comprising at least one metal layer, said method comprising steps of:- providing the metal layer, the metal layer being made of a metal which has a melting temperature Tm, the metal layer having at least one surface which has a first color; - providing a controllable concentrated heat source; and - first heating the at least one surface of the metal layer with the controllable concentrated heat source, to a first heating temperature T1 comprised in a temperature range [Tmin; Tmax], Tmax being lower than the melting temperature Tm, the first heating step comprising a substep of changing the first color of the at least one surface into a second color, different from the first color.The present invention also relates to a metal transaction card obtained by said method. Figure for abstract: Figure 1.

Description

Title of the invention: Method for manufacturing a metal transaction card and metal transaction card thus obtained Technical field

[0001] The present invention relates to a method of manufacturing a metal transaction card and a metal transaction card obtained by said method. Background of the invention

[0002] Cards, such as transaction cards, are typically made from thermoplastic materials, such as polyvinyl chloride (PVC) and polyethylene terephthalate (PET). However, these transaction cards are susceptible to damage or destruction if exposed to harsh environments. For example, transaction cards exposed to moisture and sunlight may warp, crack, and become unusable. In addition, thermoplastic transaction cards can be easily bent or may be broken or cut, damaging the transaction card and rendering it unusable.

[0003] Accordingly, it has been proposed to manufacture a card containing at least one layer of metal or consisting entirely of metal (hereinafter referred to as a "metal card") in order to provide the card with strength and durability and to enable it to withstand exposure to the elements, such as moisture or sunlight.

[0004] Furthermore, as transaction cards have become fashion accessories reflecting the lifestyle and values ​​of their users, metal cards, compared to the known thermoplastic cards, constitute a valuable marketing asset for banks to strengthen the bond with their customers and build a lasting relationship. Metal cards are used to attract not only high-end customers, but also young, affluent customers.

[0005] In this context, it is particularly interesting to allow customers to personalize their metal cards, for example by allowing them to select or download the design of their future card instead of it being assigned to them automatically, so that each customer has a truly unique metal card.

[0006] US7494057B2 discloses a method of manufacturing a single transaction card comprising a continuous metal layer, for example titanium or stainless steel, over an entire surface of the single transaction card, the method comprising the step of etching, via a laser beam, a surface of the continuous metal layer to provide a pattern of varying depth in said surface by removing a portion of said surface.

[0007] This laser engraving step is accompanied by a melting of said surface caused by the laser beam, then a recrystallization of said surface when it is cooled to confer a color to said surface.

[0008] Thus, the coloring of said surface results from two phase transitions of the state of the matter of the continuous metal layer, namely melting (liquid) then recrystallization (solid).

[0009] In addition to being irreversible due to these phase transitions, this coloring process only allows a glassy color finish to be obtained and is only possible during a laser engraving step of said surface (i.e. the removal of material from said surface).

[0010] It is therefore necessary to provide metal cards, such as metal transaction cards, which can be easily personalized, in particular with the desired personalization characteristics, and in particular by using a controlled and reproducible personalization process. Summary of the invention

[0011] The present invention aims to provide, according to a first aspect, a method of manufacturing a metal transaction card comprising at least one metal layer, said method comprising steps consisting of:

[0012] - providing the metal layer, the metal layer being made of a metal having a melting temperature Tm, the metal layer having at least one surface which has a first color;

[0013] - providing a controllable concentrated heat source, preferably a source laser, more preferably a MOPA (Master Oscillator Power Amplifier) ​​laser system; and

[0014] - first heating the at least one surface of the metal layer with the source of controllable concentrated heat, at a first heating temperature Tl included in a temperature range [Tmin; Tmax], Tmax being lower than the melting temperature Tm, the first heating step comprising a substep of changing the first color of the at least one surface into a second color, different from the first color.

[0015] A metal layer made of a metal means that the metal layer is made of a metal or an alloy of metals.

[0016] Here, Tmin is less than Tmax.

[0017] The terms "a second color different from the first color" mean that the first color and the second color may have a Delta E contrast value equal to or greater than 4, preferably equal to or greater than 15, and more preferably equal to or greater than 30.

[0018] The Delta E contrast is here advantageously the measurement of the color difference defined by the International Committee on Illumination (CIE). A process is for example described in the CIE standard of 1976: ISO 11664.

[0019] Thus, for example, Delta E, dE or AE, is defined as a measure of Euclidean distance between two colors considered in a color space. The formula established in 1976 by the CIE is for example:

[0020] AE* = ^[(L*2 -L*)!2 + (a*2 -a*)!2 + (b*2 -b*)]!2

[0021] where:

[0022] L*ba*i and b*i are the coordinates in the CIE-Lab color space of one of the two colors, and

[0023] L*2, a*2 and b*2 are those of another of the two colors.

[0024] However, there are other formulas for calculating Delta E (CIE 1976, CIE 1994, CIE 2000, CMC).

[0025] In the present invention, since Tmax is lower than the melting temperature Tm, the sub-step of changing the first color of the at least one surface into a second color, different from the first color, is carried out without there being any melting of the at least one surface during the color change, i.e. without phase transition of the material of the at least one surface.

[0026] Furthermore, the sub-step of changing the first color of the at least one surface into a second color, different from the first color, is carried out without any etching of the at least one surface, i.e. without any removal of material from the at least one surface.

[0027] Therefore, the present invention has several advantages.

[0028] First, the sub-step of transforming the first color of the at least one surface into a second color, different from the first, is reversible.

[0029] Second, the at least one surface bearing the second color may have a different surface finish, in particular a matte surface finish, compared to the known glassy surface finish of prior art metal transaction cards. The surface effect is thus different, which makes it possible to improve the personalization and / or identification of the metal transaction cards.

[0030] The matte surface finish may be determined by measuring the average surface roughness (Ra) value of the at least one surface having the second color.

[0031] The Ra value can be measured in accordance with ISO 25178.

[0032] For example, the Ra value is measured by profilometry.

[0033] The matte surface finish may correspond to a Ra value of the at least one surface which has the second color of between 0.15 pm and 0.6 pm.

[0034] The Ra value of the at least one surface when it has the first color, i.e. before the first heating step, and the Ra value of the at least one surface when it has the second color, i.e. after the first heating step, may remain essentially equal.

[0035] In particular, the Ra value of the at least one surface when it has the first color, i.e. before the first heating step, and the Ra value of the at least one surface when it has the second color, i.e. after the first heating step, may be between 0.15 pm and 0.6 pm.

[0036] Tmin is the minimum temperature at which the sub-step of changing the first color of the at least one surface into a second color is preferably carried out.

[0037] Tmax is the maximum temperature at which the sub-step of changing the first color of the at least one surface into a second color is preferably carried out, said change of the first color into a second color being a reversible phenomenon.

[0038] According to one example, at atmospheric pressure, Tmin is generally equal to about 193°C and Tmax is generally equal to about 445°C, when the metal layer is made of 305 grade stainless steel.

[0039] According to another example, at atmospheric pressure, Tmin is generally equal to about 198°C and Tmax is generally equal to about 1094°C, when the metal layer is made of tungsten.

[0040] According to an exemplary embodiment, Tmin is generally greater than or equal to 100°C.

[0041] According to an exemplary embodiment, Tmax is generally less than or equal to 3,500°C.

[0042] During the first heating step, the at least one surface that has the first color is exposed to the controllable concentrated heat source.

[0043] The first heating step may comprise a sub-step of rearrangement of the crystal lattice of the at least one surface having the first color.

[0044] The sub-step of rearrangement of the crystal lattice of the at least one surface having the first color can be reversible.

[0045] This reversibility is permitted because the sub-step of rearrangement of the crystal lattice of the at least one surface having the first color is carried out without melting of the at least one surface having the first color, the temperature Tmax being lower than the melting temperature Tm.

[0046] The first heating step may include a substep of providing radiant heating, convection heating, localized induction heating, high frequency vibration induced heating and / or a laser beam by the controllable concentrated heat source.

[0047] For example, radiant heating is microwave heating.

[0048] In an exemplary embodiment, the first heating step comprises a substep of providing a laser beam by the controllable concentrated heat source.

[0049] The laser beam may be directed toward the metal layer, preferably toward the at least one surface having the first color.

[0050] The laser beam may be orthogonal to the at least one surface having the first color.

[0051] For example, the laser beam may be a pulsed laser beam.

[0052] The use of such a pulsed laser beam can make it possible to obtain the second color with satisfactory precision.

[0053] Accuracy can be determined by measuring a Delta E contrast value between the second target color and the second obtained color.

[0054] Satisfactory precision may correspond to a contrast value Delta E < 5, preferably to a contrast value Delta E < 4, more preferably to a contrast value Delta E < 3, and even more preferably to a contrast value Delta E < 2.

[0055] For example, the pulsed laser beam may have a pulse energy density of between 0.002 J / mm2 and 74 J / mm2, preferably between 0.002 J / mm2 and 1.747 J / mm2, more preferably between 0.01 J / mm2 and 1.747 J / mm2, even more preferably between 0.02 J / mm2 and 0.28 J / mm2, and in particular between 0.04 J / mm2 and 0.14 J / mm2.

[0056] For example, the pulsed laser beam may have a pulse frequency of between 1 kHz and 1000 kHz, preferably between 2 kHz and 1000 kHz, more preferably between 10 kHz and 750 kHz, and even more preferably between 40 kHz and 500 kHz.

[0057] For example, the pulse frequency of the pulsed laser beam is between 1 kHz and 20 kHz, or between 20 kHz and 1000 kHz.

[0058] For example, the pulse frequency of the pulsed laser beam is between 25 kHz and 500 kHz, preferably between 50 kHz and 450 kHz, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0059] For example, the pulsed laser beam, when between 1 kHz and 20 kHz, may have a pulse energy density between 0.01 J / mm2 and 74 J / mm2, preferably between 0.02 J / mm2 and 0.28 J / mm2, and more preferably between 0.04 J / mm2 and 0.14 J / mm2.

[0060] For example, the pulsed laser beam, when between 20 kHz and 1000 kHz, may have a pulse energy density between 0.002 J / mm2 and 1.747 J / mm2.

[0061] For example, the pulsed laser beam may have a pulse duration of between 1 ns and 1000 ns, preferably between 1 ns and 400 ns, and more preferably between 2 ns and 300 ns.

[0062] For example, the pulse duration of the pulsed laser beam is between 2 ns and 250 ns, preferably between 4 ns and 200 ns, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0063] For example, the pulsed laser beam may have a scanning speed of between 1 mm / s and 3,000 mm / s, and preferably between 1,000 mm / s and 3,000 mm / s.

[0064] For example, the scanning speed of the pulsed laser beam is between 1400 mm / s and 2200 mm / s, preferably between 1600 mm / s and 2000 mm / s, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0065] The pulsed laser beam may have a wavelength of 1064 nm.

[0066] The first heating step may comprise a sub-step of adjusting the pulsed laser beam with at least one of the parameters described above.

[0067] For example, MOPA (Master Oscillator Power Amplifier) ​​laser systems are particularly suitable for providing a pulsed laser beam with at least one of the parameters mentioned above.

[0068] The first heating step can last from 1 min to 10 min, preferably from 2 min to 8 min, more preferably from 3 min to 6 min.

[0069] The manufacturing method may comprise a second heating step of at least a portion of at least one surface which has the second color with the controllable concentrated heat source, at a second heating temperature T2 which is included in the temperature range [Tmin; Tmax], the second heating step comprising a sub-step of changing the second color of the at least one surface into a third color, different from the second color.

[0070] In an exemplary embodiment, the second heating temperature T2 is equal to the first heating temperature TL

[0071] The terms "a third color different from the second color" mean that the second color and the third color may have a Delta E contrast value equal to or greater than 4, preferably equal to or greater than 15, and more preferably equal to or greater than 30.

[0072] The third color may be the same or different from the first color.

[0073] For example, when the third color is identical to the first color, the third color and the first color may have a Delta E contrast value of less than 8, preferably less than 5, and more preferably less than 3.

[0074] For example, when the third color is different from the first color, the third color and the first color may have a contrast value Delta E equal to or greater than 4, preferably equal to or greater than 15, and more preferably equal to or greater than 30. The manufacturing method may comprise a step of annealing the metal layer.

[0075] For example, the step of annealing the metal layer can be carried out at a temperature between 980°C and 1150°C, preferably at a temperature between 990°C and 1140°C, more preferably at a temperature between 1000°C and 1130°C, and even more preferably at a temperature between 1010°C and 1121°C.

[0076] In an exemplary embodiment, the step of annealing the metal layer is carried out at a temperature above 800°C, preferably above 900°C, more preferably above 1000°C, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0077] For example, the step of annealing the metal layer is carried out at a temperature between 1000°C and 1150°C, preferably between 1005°C and 1130°C, more preferably between 1010°C and 121°C, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0078] For example, the step of annealing the metal layer may be carried out for a period of time greater than 6 minutes, preferably for a period of 12 minutes to 75 minutes.

[0079] In an exemplary embodiment, the step of annealing the metal layer is carried out for a period of time of between 1 and 10 minutes, preferably between 1 and 6 minutes, in particular when the metal layer is made of stainless steel, such as for example 305 grade stainless steel.

[0080] For example, the step of annealing the metal layer can be carried out before the first heating step.

[0081] The manufacturing method may comprise a step of treating the metal layer with ions.

[0082] The ions can be anions.

[0083] For example, the anions are chosen from the group consisting of nitrates, nitrites, acetates, carbonates and their mixtures.

[0084] For example, the step of treating the metal layer with ions can be carried out before the first heating step.

[0085] The manufacturing method may comprise a step of covering at least one surface having the second color with at least one protective layer.

[0086] For example, the protective layer is curable, in particular curable with ultraviolet rays (UV curable) and / or heat curable.

[0087] The protective layer may comprise at least one adhesive.

[0088] For example, the adhesive is curable, including ultraviolet curable (UV curable) and / or heat curable.

[0089] For example, the adhesive comprises a resin.

[0090] For example, the resin is selected from the group consisting of methacrylates, acrylates, polyesters, polyurethanes, epoxies, vinyl esters and mixtures thereof.

[0091] For example, the resin is a bio-sourced resin.

[0092] In an exemplary embodiment, the covering step may comprise a sub-step of coating the at least one surface having the second color with the adhesive.

[0093] For example, the substep of coating the at least one surface having the second color with adhesive is carried out by spin coating, dip coating, spray coating, blade coating, roller coating and / or any other coating technique.

[0094] In another exemplary embodiment, the covering step may comprise a sub-step of providing the protective layer, then a sub-step of applying the protective layer to the at least one surface having the second color.

[0095] For example, the protective layer, in particular the adhesive, may be in direct contact with the at least one surface having the second color.

[0096] For example, the covering step may be performed after the first heating step.

[0097] For example, the manufacturing method may include a step of curing the protective layer.

[0098] For example, the curing step may be performed by applying UV and / or heat to the protective layer.

[0099] For example, the manufacturing method may include a step of laminating the protective layer that covers the at least one surface having the second color with the metallic layer.

[0100] For example, the laminating step may be performed after the covering step.

[0101] For example, the laminating step may be performed by applying heat to the less on the protective layer which covers the at least one surface having the second color, in particular a temperature higher than a curing temperature of the protective layer, in particular a temperature between 40°C and 200°C.

[0102] For example, the laminating step may be performed by applying pressure at least to the protective layer that covers the at least one surface having the second color.

[0103] For example, the pressure may be greater than 90 kPa, preferably greater than 95 kPa, and more preferably greater than 96.5 kPa.

[0104] For example, the pressure may be less than 1034 kPa, preferably between 90 kPa and 1034 kPa, more preferably between 95 kPa and 1034 kPa, and even more preferably between 96.5 kPa and 1034 kPa.

[0105] When the at least one surface having the second color is covered with the protective layer and the manufacturing method comprises the step of the second heating, the manufacturing method may comprise a step of removing the protective layer which covers the at least one surface having the second color.

[0106] The step of removing the protective layer which covers the at least one surface having the second color can be carried out before the step of the second heating.

[0107] The present invention aims to provide, according to a second aspect, an apparatus for implementing the manufacturing method as described above, the apparatus comprising: - a support element configured to receive a metal layer, the metal layer being made of a metal having a melting temperature Tm, the metal layer having at least one surface having a first color, and - a controllable concentrated heat source,

[0108] the controllable concentrated heat source being configured to heat the at least one surface of the metal layer to a first heating temperature Tl comprised in a temperature range [Tmin; Tmax], Tmax being lower than the melting temperature Tm.

[0109] For example, the controllable concentrated heat source may be a laser source, a radiant heating source, a convection heating source, a localized induction heating source, and / or a high frequency vibration induced heating source.

[0110] For example, the radiant heating source is a microwave heating source.

[0111] For example, the controllable concentrated heat source is a laser source.

[0112] For example, the laser source can be chosen from the group consisting of the MOPA (Master Oscillator Power Amplifier) ​​laser systems.

[0113] For example, the laser source may be configured to provide a pulsed laser beam.

[0114] For example, the pulsed laser beam may exhibit at least one of the characteristics following: - a pulse energy density between 0.002 J / mm2 and 74 J / mm2, of preferably between 0.002 J / mm2 and 1.747 J / mm2, more preferably between 0.01 J / mm2 and 1.747 J / mm2, even more preferably between 0.02 J / mm2 and 0.28 J / mm2, and in particular between 0.04 J / mm2 and 0.14 J / mm2; - a pulse duration of between 1 ns and 1000 ns, preferably between 1 ns and 400 ns, and more preferably between 2 ns and 300 ns; - a pulse frequency between 1 kHz and 1000 kHz, preferably between 2 kHz and 1000 kHz, more preferably between 10 kHz and 750 kHz, and even more preferably between 40 kHz and 500 kHz; - a scanning speed of between 1 mm / s and 3,000 mm / s, and preferably between 1,000 mm / s and 3,000 mm / s; and / or - a wavelength of 1064 nm.

[0115] The present invention aims to provide, according to a third aspect, a metal transaction card obtained by the manufacturing method as described above, the metal transaction card comprising at least one metal layer having at least one surface having a second color, the at least one surface having a matte surface finish.

[0116] The metallic layer of the metallic transaction card according to the present invention comprises at least one surface having a novel surface finish, namely a matte surface finish, compared to the known glassy surface finish of prior art metallic transaction cards. This novel surface effect makes it possible to improve the personalization and / or identification of metallic transaction cards.

[0117] The metal transaction card may be a contactless card, a magnetic stripe card, a credit card, a debit card, a stored value card, a payment card, a prepaid card, a phone card, a smart card, a barcode card, a reward card, an identification card, an access card, an information storage card, an e-commerce card and any other type of transaction card.

[0118] The metal transaction card, in particular the metal layer, may comprise at least one pattern, the at least one pattern being formed, in particular in part, by the at least one surface of the metal layer which has the second color.

[0119] The pattern may include at least one of a graphic, an alphanumeric character, and / or a 2D barcode, including QR codes.

[0120] The presence of such patterns can make it possible to further improve the personalization and / or identification of the metal transaction card.

[0121] The metal transaction card may have width and length dimensions consistent with those of so-called ID-1, ID-2 or ID-3 cards, preferably ID-1, as defined in ISO / IEC 7810:2019.

[0122] The metal layer may extend substantially across the entire length dimension of the metal transaction card and substantially across the entire width dimension of the metal transaction card.

[0123] The metal transaction card may include at least one protective layer that covers the at least one surface of the metal layer having the second color.

[0124] This protection can make it possible to protect at least one surface of the metal layer which has the second color, in particular against external wear and physical or chemical damage.

[0125] The protective layer may comprise a polyvinyl chloride (PVC) layer, particularly a pre-conditioned polyvinyl chloride (PVC) layer.

[0126] The protective layer may comprise at least one adhesive.

[0127] For example, the adhesive is placed between the polyvinyl chloride (PVC) layer and the at least one surface of the metal layer that has the second color.

[0128] For example, the adhesive is a cured adhesive, including an ultraviolet cured (UV cured) adhesive and / or a heat cured adhesive.

[0129] For example, the adhesive comprises a resin.

[0130] For example, the resin is selected from the group consisting of methacrylates, acrylates, polyesters, polyurethanes, epoxies, vinyl esters and mixtures thereof.

[0131] For example, the resin is a bio-sourced resin.

[0132] The protective layer, in particular the adhesive, may be in direct contact with the at least one surface of the metal layer which has the second color.

[0133] In an exemplary embodiment, the protective layer extends essentially over the entire length dimension of the metal layer and essentially over the entire width dimension of the metal layer.

[0134] In another exemplary embodiment, the protective layer does not extend substantially over the entire length dimension of the metal layer and / or does not extend substantially over the entire width dimension of the metal layer. In this case, the protective layer consists of a patch.

[0135] The protective layer may have a thickness of between 3 pm and 230 pm, preferably between 4 pm and 225 pm, more preferably between 5 pm and 220 pm.

[0136] The metal layer may be made of any metal or metal alloy.

[0137] For example, the metal layer comprises stainless steel, such as 305 or 316 stainless steel, tungsten, aluminum, titanium, copper, brass, tin, iron oxide, gallium, indium, or an alloy thereof.

[0138] The metal layer may comprise an ionic treatment, preferably with anions, preferably chosen from the group consisting of nitrates, nitrites, acetates, carbonates and their mixtures.

[0139] The metal layer may have a thickness of between 280 pm and 380 pm, preferably between 300 pm and 360 pm, more preferably between 310 pm and 350 pm, and even more preferably between 320 pm and 340 pm. Brief description of the drawings

[0140] Other features and advantages of the invention will also emerge from the description which follows.

[0141] In the attached drawings, given as non-limiting examples: - [Fig.l] shows a flowchart illustrating an exemplary embodiment of a method for manufacturing a metal transaction card according to the present invention, - [Fig.2] shows an example of carrying out a step of providing a metal layer of the manufacturing method according to the present invention, - [Fig.3] shows an exemplary embodiment of a step of providing a controllable concentrated heat source of the manufacturing method according to the present invention, - [Fig.4] shows an example of carrying out a first heating step of the manufacturing method according to the present invention, - [Fig.5] shows an example of carrying out a sub-step of changing the first color of the at least one surface into a second color of the manufacturing method according to the present invention, and - [Fig.6] shows an exemplary embodiment of a metal transaction card according to the present invention. Detailed description of the invention

[0142] [Fig.l] shows a flowchart illustrating an exemplary embodiment of a method for manufacturing a metal transaction card comprising at least one metal layer, said method comprising: - a step S1 consisting of providing the metal layer, the metal layer being made of a metal having a melting temperature Tm, the metal layer having at least one surface having a first color; - a step S2 consisting of providing a controllable concentrated heat source; and - a step S3 consisting of first heating the at least one surface of the metal layer with the controllable concentrated heat source, to a first heating temperature Tl included in a temperature range [Tmin; Tmax], Tmax being lower than the melting temperature Tm, the first step of heating S3 comprising a substep S31 consisting of changing the first color of the at least one surface into a second color, different from the first color.

[0143] [Fig.2] shows an example of the implementation of step SI of providing the metal layer 1.

[0144] The metal layer 1 has at least one surface 2 which has a first color.

[0145] The metal layer 1 is made of a pure metal or a metal alloy of which the melting temperature is Tm.

[0146] The metal layer 1 can be made of any metal or metal alloy.

[0147] For example, the metal layer 1 comprises stainless steel, such as for example 305 or 316 grade stainless steel, tungsten, aluminum, titanium, copper, brass, tin, iron oxide, gallium, indium or alloys thereof.

[0148] The metal layer 1 may have a thickness of between 280 pm and 380 pm, preferably between 300 pm and 360 pm, more preferably between 310 pm and 350 pm, and even more preferably between 320 pm and 340 pm.

[0149] [Fig.3] illustrates an exemplary embodiment of step S2 consisting of providing a controllable concentrated heat source 3.

[0150] The controllable concentrated heat source 3 is configured to heat at least one surface 2 of the metal layer 1 which has the first color.

[0151] The controllable concentrated heat source 3 may be a laser source, preferably a MOPA (Master Oscillator Power Amplifier) ​​laser system.

[0152] [Fig.4] shows an example of step S3 of the first heating.

[0153] In this exemplary embodiment, step S3 comprises a sub-step consisting of providing a laser beam 4 by the controllable concentrated heat source 3.

[0154] In this exemplary embodiment, the laser beam 4 is directed towards the at least one surface 2 of the metal layer 1 which has the first color.

[0155] The laser beam 4 is preferably a pulsed laser beam.

[0156] In an exemplary embodiment, step S3 of the first heating comprises a sub- step of adjusting the pulsed laser beam with at least one of the following parameters: - a pulse energy density of between 0.002 J / mm2 and 74 J / mm2, preferably between 0.002 J / mm2 and 1.747 J / mm2, more preferably between 0.01 J / mm2 and 1.747 J / mm2, even more preferably between 0.02 J / mm2 and 0.28 J / mm2, and in particular between 0.04 J / mm2 and 0.14 J / mm2; - a pulse duration of between 1 ns and 1000 ns, preferably between 1 ns and 400 ns, and more preferably between 2 ns and 300 ns;

[0157]

[0158]

[0159]

[0160]

[0161] - a pulse frequency between 1 kHz and 1000 kHz, preferably between 2 kHz and 1000 kHz, more preferably between 10 kHz and 750 kHz, and even more preferably between 40 kHz and 500 kHz; - a scanning speed of between 1 mm / s and 3,000 mm / s, and preferably between 1,000 mm / s and 3,000 mm / s; and / or - a wavelength of 1064 nm. The first heating step S3 may comprise a sub-step of rearrangement of the crystal lattice of the at least one surface having the first color. This sub-step of rearrangement of the crystal lattice of the at least one surface having the first color can be reversible. As illustrated in [Fig.5], the first heating step S3 comprises a sub-step S31 of changing the first color of the at least one surface 2 into a second color, different from the first color. Table 1 below shows examples of operating conditions for performing the substep of changing the first color of the at least one surface to a second color, as shown in the first column of Table 1. These operating conditions were determined for a first heating step using: - a metal layer of 305 grade stainless steel with a thickness of 330 pm and at least one surface of which has a silver color (i.e. a natural color of stainless steel) as a first color; - a 20-watt MOPA laser system as a controllable concentrated heat source with a wavelength of 1064 nm; - continuous height calibration for optimal laser focus; - a laser beam angle orthogonal to the at least one surface of the metal layer; and - a duration of the first heating stage of 4 minutes and 24 seconds. Second Color Power (%) Scan Speed ​​(mm / s) Pulse Frequency (kHz) Pulse Duration (ns) Fill Style Fill Spacing (mm) Crossing Angle Black 80 2000 150 8 Bidirectional 0.0010 N / A Red 90 2000 250 14 Bidirectional 0.0010 N / A Dark Blue 100 2,000 300 4 Bidirectional 0.0010 N / A Medium Blue 100 2,000 350 4 Bidirectional 0.0010 N / A Light Blue 100 2,000 450 4 Bidirectional 0.0010 N / A Green 100 1,600 110 8 Bidirectional 0.0010 N / A White 45 2,000 50 200 Cross / Bidirectional 0.0500 90.00 Gold 80 2,000 150 8 Bidirectional 0.0020 N / A Brown 50 1,800 200 30 Bidirectional 0.0050 N / A Purple 100 2 000 260 4 Bidirectional 0.0010 N / A Orange 75 2 000 300 8 Cross / Bidirectional 0.0020 90.00 Yellow 95 2 000 80 4 Bidirectional 0.0010 N / A

[0162] Table 1

[0163] “Fill spacing” means the distance between two beam passes laser.

[0164] “Crossing angle” is the angle between two passages of the laser beam.

[0165] The "fill style" can be "unidirectional" if the laser beam passes all go in the same direction, "bidirectional" if the laser beam passes go back and forth, and / or "cross" if the laser beam passes cross at an angle defined by the crossing angle value.

[0166] It appears that the surface modification of 305 stainless steel occurs between about 50 kHz and 450 kHz with a 20 watt laser power level set from 50% to 100%.

[0167] The impact of the surface color seems successful on 305 stainless steel, because the Most primary colors and white could be obtained.

[0168] The tests were carried out with a 20 watt laser, the color in the blue, violet and green range, showed good surface modification and coloring at 100% power.

[0169] A more powerful laser could be applied to stainless steel metal layers, especially 305 grade stainless steel metal layers.

[0170] A more powerful laser could provide a greater adjustment range and marking speed and might be necessary if other grades of stainless steel metal layers are considered for metal card manufacturing.

[0171] [Fig.6] shows an example of a metal transaction card 100 according to the present invention.

[0172] The metal transaction card 100 comprises a metal layer 40.

[0173] The metal layer 40 here comprises a through opening 43.

[0174] In this example, the metal layer 40 has a thickness of approximately 330 μm.

[0175] The metal transaction card 100 here comprises an antenna 50, located in the through opening 43 of the metal layer 40.

[0176] In this example, the antenna 50 has a thickness which is preferably equal to the thickness of the metal layer 40.

[0177] For example, the thickness of the antenna 50 is approximately 330 pm.

[0178] The metal layer 40 and the antenna 50 located inside the through opening 43 of the metal layer 40 comprise two opposite main faces 41, 42, namely an upper main face 41 and a lower main face 42.

[0179] In this exemplary embodiment, the metal transaction card 100 comprises a preconditioned polyvinyl chloride (PVC) top layer 30, and here, the preconditioned PVC top layer 30 covers the upper main face 4L

[0180] The preconditioned PVC top layer 30 is bonded to the upper main face 41 using an adhesive.

[0181] For example, the adhesive is curable, including ultraviolet curable (UV curable) and / or heat curable.

[0182] For example, the adhesive comprises a resin.

[0183] Further, the metal transaction card 100 includes an art / core top layer 20, and here, the art / core top layer 20 covers the pre-conditioned PVC top layer 30.

[0184] Next, the metal transaction card 100 includes a top overlay 10, and here, the top overlay 10 covers the top art / core layer 20.

[0185] For example, the preconditioned PVC top layer 30 has a thickness between 5 pm and 3 pm.

[0186] For example, the preconditioned PVC top layer 30 is transparent or semi-transparent.

[0187] For example, the top artistic / core layer 20 has a thickness between 127 pm and 145 pm.

[0188] For example, the upper overlay 10 has a thickness of approximately 45 pm.

[0189] For example, the upper overlay 10 is transparent or semi-transparent.

[0190] The metal transaction card 100 includes a preconditioned PVC lower layer 60, and the preconditioned PVC lower layer 60 covers the lower main face 42.

[0191] The preconditioned lower PVC layer 60 is connected to the lower main face 42 using an adhesive.

[0192] For example, the adhesive is curable, including ultraviolet curable (UV curable) and / or heat curable.

[0193] For example, the adhesive comprises a resin.

[0194] Next, the metal transaction card 100 includes an art / core bottom layer 70, and the art / core bottom layer 70 covers the pre-conditioned PVC bottom layer 60.

[0195] Next, the metal transaction card 100 includes a lower overlay 80, which covers the lower art / core layer 70.

[0196] In this exemplary embodiment, the lower overlay 80 comprises a magnetic strip 81.

[0197] For example, the preconditioned PVC bottom layer 60 has a thickness of between 5 μm and 15 μm.

[0198] For example, the preconditioned PVC bottom layer 60 is transparent or semi-transparent.

[0199] For example, the lower art / core layer 70 has a thickness between 127 pm and 145 pm.

[0200] For example, the lower overlay 80 has a thickness of approximately 45 pm.

[0201] For example, the lower overlay 80 is transparent or semi-transparent.

[0202] The method of manufacturing such a metal transaction card 100 may comprise, for example, a first lamination step, followed by a second lamination step.

[0203] The first lamination step consists of laminating the metal layer 40 and the antenna 50 located inside the through opening 43 of the metal layer 40 with the pre-conditioned PVC upper layer 30 and the pre-conditioned PVC lower layer 60, in order to obtain a pre-laminated product.

[0204] The second lamination step consists of laminating the pre-laminated product with the top art / core layer 20 and bottom art / core layer 70, as well as with top overlay 10 and bottom overlay 80, to obtain metal transaction card 100.

[0205] Such a method, according to a specific embodiment, may comprise the following steps.

[0206] For example, the method may include steps of forming the metal layer.

[0207] For example, it may include the steps of:

[0208] 1) providing the metal layer;

[0209] 2) forming the through opening in the metal layer.

[0210] For example, the method may then comprise first lamination steps.

[0211] For example, it may include the steps of:

[0212] 3) place the pre-conditioned lower PVC layer on a distribution table of resin;

[0213] 4) distribute approximately 14 g of resin on the lower layer of pre-con PVC conditioned;

[0214] 5) place the metal layer on the resin, centering the metal layer on the pre-conditioned PVC bottom layer;

[0215] 6) placing the antennas in the through opening of the metal layer;

[0216] 7) distribute approximately 14 g of resin on the metal layer;

[0217] 8) place the pre-conditioned PVC top layer on the resin;

[0218] 9) place the sheet in the vacuum chamber and treat it to a vacuum of 550 pm (29.90 inHg) or less;

[0219] 10) move the overlapped layers on the light table to check if the layer metal or antennas are misaligned, and correct alignment problems if necessary;

[0220] 11) first stratification step using a first stratification program standard production to obtain the pre-laminated product.

[0221] For example, the method may then comprise second lamination steps.

[0222] For example, it may include the steps of:

[0223] 12) cut off excess material from the pre-laminated product;

[0224] 13) combine the upper artistic / core layer, the lower artistic / core layer core, top overlay and bottom overlay on the pre-laminated product;

[0225] 14) second stratification step using a second stratification program standard production design to obtain the metal transaction card.

[0226] For example, the method may then comprise post-processing steps stratification.

[0227] For example, it may include the following steps:

[0228] 15) ultraviolet (UV) curing printing, carried out for example by printers from the Mimaki company;

[0229] 16) singularization, carried out for example using a punch or a process of milling;

[0230] 17) inspection of the metal transaction card.

[0231] Such a method can be implemented with standard metal card manufacturing machines, tools and programs, unless otherwise indicated.

[0232] In particular, the first heating step described above may be implemented before step 3) of placing the preconditioned lower PVC layer on a resin distribution table, or even before step 2) of forming the through opening in the metal layer.

[0233] The first heating step described above can therefore be implemented before any stratification step described above.

[0234] Therefore, the part of the process comprising these lamination steps remains unchanged when carrying out the first heating step as described above.

[0235] The first heating step may be followed by a step of cleaning the metal layer, if necessary.

Claims

Claims

1. A method of manufacturing a metal transaction card comprising at least one metal layer, said method comprising the steps of: - providing the metal layer, the metal layer being made of a metal having a melting temperature Tm, the metal layer having at least one surface having a first color; - providing a controllable concentrated heat source; and - first heating the at least one surface of the metal layer with the controllable concentrated heat source, to a first heating temperature Tl comprised in a temperature range [Tmin; Tmax], Tmax being lower than the melting temperature Tm, the first heating step comprising a substep of changing the first color of the at least one surface into a second color, different from the first color.

2. The method of claim 1, wherein the first heating step comprises a substep of rearranging the crystal lattice of the at least one surface that exhibits the first color.

3. The method of claim 1 or 2, wherein the first heating step comprises a substep of providing a pulsed laser beam from the controllable concentrated heat source.

4. The method of claim 3, wherein the first heating step comprises a substep of adjusting the pulsed laser beam with at least one of the following parameters: • a pulse energy density of between 0.002 J / mm2 and 74 J / mm2, preferably between 0.002 J / mm2 and 1.747 J / mm2, more preferably between 0.01 J / mm2 and 1.747 J / mm2, even more preferably between 0.02 J / mm2 and 0.28 J / mm2, and in particular between 0.04 J / mm2 and 0.14 J / mm2; • a pulse duration of between 1 ns and 1000 ns, preferably between 1 ns and 400 ns, and more preferably between 2 ns and 300 ns; • a pulse frequency between 1 kHz and 1000 kHz, preferably between 2 kHz and 1000 kHz, more preferably between 10 kHz and 750 kHz, and even more preferably between 40 kHz and 500 kHz; • a scanning speed of between 1 mm / s and 3000 mm / s, and preferably between 1000 mm / s and 3000 mm / s; and / or • a wavelength of 1064 nm.

5. A method according to any one of claims 1 to 4, comprising a step of second heating at least a portion of the at least one surface which has the second color with the controllable concentrated heat source, at a second heating temperature T2 which is within the temperature range [Tmin; Tmax], the second heating step comprising a substep of changing the second color of the at least one surface into a third color, different from the second color.

6. A method according to any one of claims 1 to 5, wherein the method comprises a step of covering the at least one surface which has the second color with at least one protective layer.

7. The method of claim 6, wherein the covering step is performed after the first heating step.

8. A method according to claim 6 or 7, comprising a step of laminating the protective layer with the metal layer.

9. A metal transaction card obtained by the manufacturing method according to any one of claims 1 to 8, the metal transaction card comprising at least one metal layer having at least one surface which has a second color, the at least one surface having a matte surface finish.

10. A metal transaction card according to claim 9, comprising at least one pattern, the at least one pattern being formed by the at least one surface of the metal layer which has the second color.

11. A metal transaction card according to claim 9 or 10, comprising at least one protective layer which covers the at least one surface of the metal layer which has the second color.

12. A metal transaction card according to claim 11, wherein the protective layer comprises at least one adhesive, the adhesive preferably being a cured adhesive, especially an ultraviolet cured adhesive. (UV cured) and / or a heat cured adhesive.

13. A metal transaction card according to claim 11 or 12, wherein the protective layer has a thickness of between 1 pm and 25 pm, preferably between 3 pm and 20 pm, more preferably between 5 pm and 15 pm.

14. A metal transaction card according to any one of claims 9 to 13, wherein the metal layer has a thickness of between 280 pm and 380 pm, preferably between 300 pm and 360 pm, more preferably between 310 pm and 350 pm, and even more preferably between 320 pm and 340 pm.

15. A metal transaction card according to any one of claims 9 to 14, wherein the metal layer comprises stainless steel, tungsten, aluminum, titanium, copper, brass, tin, iron oxide, gallium, indium or an alloy thereof.

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