Metal, ceramic, or ceramic coated transaction card with window or window pattern, and optionally with backlight

Abstract

To provide a metal, ceramic, or ceramic-coated transaction card with a window or a window patter, and optionally with a backlight.SOLUTION: A transaction card (1900) includes at least one metal layer (1910) including one or more opening portions (1920, 1930) inside. A light guide (1933) is disposed below the metal layer. The light guide includes a light output end and a light input end. The light output end is positioned to transmit a light through at least the one or more opening portions of the metal layer. In order to transmit the light in the light input end of the light guide, at least one LED (1935) is positioned.SELECTED DRAWING: Figure 19A

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. patent application Ser. No. 16 / 751,285, filed Jan. 24, 2020, entitled "METAL, CERAMIC, OR CERAMIC-COATED TRANSACTION CARDS WITH WINDOW OR WINDOW PATTERN AND OPTIONALLY BACKLIT," the entire contents of which are incorporated herein by reference for all purposes. [Background technology]

[0002] Transaction cards can have any number of features to differentiate one offering from another. Consumers have demonstrated a demand for metal cards because of their durability and overall premium feel compared to plastic. Ceramic cards offer similar durability along with a unique and desirable overall premium feel. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Patent No. 5,412,199 [Patent Document 2] U.S. Patent No. 5,434,405 [Patent Document 3] U.S. Patent No. 5,608,203 [Patent Document 4] U.S. Patent No. 6,902,116 [Patent Document 5] U.S. Patent No. 7,997,503 [Patent Document 6] US Patent Application Publication No. 2006 / 0086802 [Patent Document 7] U.S. Patent No. 9,665,818 [Patent Document 8] International Publication No. 2013 / 131153 [Patent Document 9] U.S. Patent No. 10,406,734 [Patent Document 10] U.S. Patent No. 9,390,366 [Patent Document 11] US Patent Application Publication No. 2014 / 0224881

[0004] Patent documents 1 to 3 disclose a credit card with a plastic substrate with a transparent area forming a magnifying lens, such as a Fresnel lens, that allows the card to be used as a magnifying lens to read small print on transaction receipts, etc. Patent document 4 discloses a transaction card with a transparent window that has collimating properties for focusing LED light.

[0005] U.S. Patent No. 5,629,493 discloses a card having a plastic substrate with a transparent window on which a fixed set of elongated segments is printed that, when superimposed over a display of a dynamic visual code associated with the set of elongated segments, reveals the visual code to a viewer looking through the window. Such a card therefore has information printed on the window that is essentially functional in that the printed information on the window must be in pattern alignment with the elongated segments associated with the visual code.

[0006] Providing a card with a primarily metallic, ceramic, or ceramic-coated body, e.g., metal, allows for a card with a certain look and feel (e.g., weight) not available with plastic cards, and the inclusion of a transparent window within such a card provides desirable differentiation from other card offerings. Metal and / or ceramic cards are generally more expensive to produce and therefore may be presented as premium cards targeted at cardholders who have a higher net worth than a certain level, are members of a select group of customers who are valuable to the card issuer, and / or are willing to pay a significant annual fee. Holders of such premium cards may not recognize the need for a magnifying glass and therefore may not want a transparent window with magnification or collimation. Holders of such cards may prefer the central majority of the transparent window to be completely devoid of any printing that would be obscured by the card, or to have the window decorated with a decorative, non-functional pattern rather than a functional pattern of elongated segments, such as the pattern described in U.S. Patent No. 5,629,499, which tends to be aesthetically pleasing. Embedding a transparent window within a metal and / or ceramic frame can present different manufacturing and structural challenges and opportunities than the card types described in the above references.

[0007] Card users and manufacturers often desire to incorporate designs that are visually and / or tactilely perceptible from at least one surface of the card. For example, Patent Document 6 discloses a gemstone card in which gemstones are embedded within a plastic card. Card issuers and cardholders may be interested in creating designs that provide an appearance similar to the pattern of gemstones, without the labor-intensive steps and expense of having to embed many individual gemstones within a card. Summary of the Invention

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

[0009] The metal layer may have at least one discontinuity extending from the periphery of the card to at least one of the at least two openings in the metal layer. The at least one discontinuity may be coupled to and extend between the at least two openings. The metal layer may have a first discontinuity extending from the periphery of the card to the opening that houses the transponder module and a second discontinuity extending from the periphery of the card to the opening that houses the LED module. The card may further include at least one non-metallic layer disposed on each of the opposing surfaces of the metal layer. A printed pattern may cover the illumination area of the LED module. The LED module may be positioned within the metal layer at a location that improves RF performance of the transponder module compared to a card without the LED module.

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

[0011] Yet another embodiment may include a transaction card having a metal layer with an appearance, a thickness, a metal layer front side, a metal layer back side, and one or more windows or pockets extending through at least the front side. A transponder module and an insert may be disposed within the one or more windows or pockets, respectively. The front side of the insert visible through the window has a different appearance from the metal layer. One or more non-functional features are visible from the front surface of the card in contrast to the appearance of the front-facing surface of the insert disposed below the non-functional features. The insert is (a) non-transparent and non-translucent; or (b) transparent or translucent and configured to transmit backlight through the back surface of the card to the non-functional features. The insert is positioned within the metal layer in a location that improves RF performance of the transponder module compared to a card without the insert. In some embodiments, the non-functional features include printed features. In some embodiments, the insert is non-transparent and non-translucent but has an illuminatable front-facing surface. The insert can include an illuminable LED display, for example, an illuminable LED display powered by energy harvested from RF waves. In embodiments in which the metal layer has at least two openings, the transponder module can be positioned in one of the at least two openings and the insert can be positioned in the other of the at least two openings.

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

[0013] The illuminatable LED display may include one or more LEDs configured to emit light and a light guide or OLED module for distributing the light emitted by the one or more LEDs across an illuminated area of the front-facing surface of the insert. The illuminatable LED display may have variable lighting characteristics depending on the amount of energy harvested, as further detailed herein, and may include one or more LEDs with variable intensities and / or configured to emit the same or different wavelengths and / or configured to light up in different combinations. [Brief explanation of the drawings]

[0014] [Figure 1A] FIG. 1A depicts the front side of an exemplary transaction card according to one embodiment of the present invention having a transparent window. [Figure 1B] FIG. 1B depicts an exploded cross-sectional view of the card of FIG. 1A. [Figure 1C] FIG. 1C depicts the back side of the card of FIG. 1A. [Figure 2] FIG. 2 illustrates an exemplary sheet from which multiple cuts of the card of FIG. 1A may be made. [Figure 3] FIG. 3 depicts an exemplary card with a window having electronic components disposed thereon. [Figure 4] FIG. 4 depicts an exemplary card with multiple windows having embedded electronic components. [Figure 5] FIG. 5 depicts an exemplary card with a window having embedded electronic components. [Figure 6] FIG. 6 illustrates an exemplary card with a window having embedded electronics and an embedded antenna. [Figure 7] FIG. 7 depicts a perspective view of the front side of an exemplary card embodiment having multiple window openings. [Figure 8] FIG. 8 depicts a perspective view of the back side and insert of the exemplary card of FIG. [Figure 9]FIG. 9 depicts a close-up perspective view of the body front side and insert front side and outer periphery of the exemplary card of FIG. [Figure 10A] FIG. 10A depicts a plan view of an exemplary card having multiple window openings cut in a pattern. [Figure 10B] FIG. 10B depicts a plan view of an exemplary card having multiple narrow slit window openings cut into patterns that collectively form alphanumeric characters. [Figure 10C] FIG. 10C depicts a top view of an exemplary card having multiple narrow slit window openings each cut into an alphanumeric pattern. [Figure 11] FIG. 11 depicts a cross-sectional view of an exemplary card having multiple window openings on its front side. [Figure 12] FIG. 12 depicts a cross-sectional view of the exemplary card of FIGS. [Figure 13] FIG. 13 depicts a cross-sectional view of the window area of an exemplary card in which multiple window openings are filled or partially filled with protruding insert material. [Figure 14] FIG. 14 depicts a cross-sectional view of the window area of an exemplary card in which multiple window openings are filled or partially filled with a translucent or transparent material that is different from the insert material. [Figure 15] FIG. 15 depicts a cross-sectional view of the window area of an exemplary card embodiment in which multiple window openings are filled or partially filled with translucent or transparent material protruding from a layer or coating disposed on the obverse side. [Figure 16] FIG. 16 depicts a cross-sectional view of the window area of an exemplary card embodiment in which multiple window openings are filled or partially filled with translucent or transparent material protruding from a layer or coating disposed beneath the obverse side. [Figure 17]FIG. 17 depicts a cross-sectional view of the window area of an exemplary card embodiment in which multiple window openings are filled or partially filled with translucent or transparent material from multiple layers or coatings disposed on the front and back sides. [Figure 18] FIG. 18 illustrates a cross-sectional view of the window area of an exemplary card embodiment in which a light guide transmits light through multiple window openings. [Figure 19A] FIG. 19A depicts a top view of an exemplary transaction card including a printed design that is backlit by an LED module. [Figure 19B] FIG. 19B depicts a cross-sectional view of the card of FIG. 19A. [Figure 19C] FIG. 19C illustrates an exemplary LED module including a light guide with side-firing LEDs. DETAILED DESCRIPTION OF THE INVENTION

[0015] 1A-1C depict an exemplary transaction card 100 comprised of a relatively thick body 102, a window insert 112, and a backing layer 120. The body 102 has a thickness (T), a front side 104, a back side 106, and a hole 108 extending from the front side to the back side. As depicted in FIGS. 1A and 1C, the hole 108 has a circular perimeter; however, it should be understood that the perimeter of the hole can take any geometric shape (e.g., oval, triangular, square, rectangular, or any regular or irregular polygonal shape having three or more sides), or the hole can have a perimeter that includes a combination of curved and / or straight line segments that do not fit into any of the geometric categories described above. Similarly, it should be understood that the transparent or translucent window may be of any size characterized by its overall area, so long as its overall area is smaller than the area of the body 102, and is preferably contained entirely within the area of the card (i.e., the periphery of the window is positioned entirely radially inward of the periphery of the body).

[0016] A non-magnifying window insert 112 having a front side 114, a back side 116, the same thickness (T) as the body 102, and a periphery that matches the periphery of the hole 108 is disposed within the hole. The window can be both non-magnifying and non-collimating. A "matching" periphery means that the window insert has the same periphery as the periphery of the hole, but is sufficiently smaller in diameter (or its equivalent) to be inserted into the hole without the need for a press fit and with no gap, or at most a gap that is nearly imperceptible to the human eye, in the boundary region between the inner edge of the hole and the outer edge of the insert. Similarly, "same" thickness means that the window insert and the metal body have the same thickness to the desired level of precision within acceptable tolerances, it being recognized that such acceptable tolerances may include thickness differences that are perceptible to the human touch or that account for the thickness of printed layers on the body.

[0017] In some embodiments, the window insert is devoid of functional printed content on either its front or back side (or embedded therein). Absence of “functional printed content” means that the insert, in some embodiments, does not have any content printed thereon (not shown), or, in other embodiments, any content printed thereon (e.g., the ship graphic 118 depicted in FIG. 1 ) is purely decorative in nature and is not intended for use in connection with, for example, an authentication or validation scheme implemented by placing a window over the corresponding graphic. Instead of or in addition to printing, graphics or other content placed within the window may also be carved, etched, or otherwise cut into the window. Content carved, etched, or otherwise cut within the window may also be non-functional, including aesthetic content resembling a 3D relief, for example, to provide a cameo-like appearance. In other embodiments, as described further herein, the window can include electronic components (e.g., LEDs) mounted thereon or therein, in which case, preferably, “invisible” or minimally visible (not visible to the naked human eye in ambient lighting without careful scrutiny) traces can be printed or otherwise disposed thereon. Such traces connect the LEDs to electrical traces within the body, which can be connected to a hidden power source within the body or to a source and / or sink of an electrical signal. In some embodiments, the LEDs can include backlight LEDs. The window can include a light guide that transmits light from a light source, such as an LED positioned at an input surface of the light guide, to an output surface of the light guide. While it is understood that all electrical signals have some inherent output, the term “output” as used herein refers to an output for powering an electrical feature, while the term “electrical signal” as used herein refers to a signal that is intended to convey information rather than provide an output.Thus, the electrical impulse traveling to the electrical feature and from there to any connected components may include an output, an electrical signal, or a combination thereof.

[0018] "Non-magnifying" means that the window insert does not function as a magnifying lens (i.e., an object at a given distance viewed through the window insert appears the same size as if it were not viewed through the window). "Non-collimating" means that the window does not focus any wavelength of radiation (not limited to visible light) passing through the window to a focal point. The window may also be light-dispersing. The window insert is non-metallic and preferably comprises polished polycarbonate, but may also comprise glass or any transparent plastic or resin known in the art. In some embodiments, the window insert can have a primarily transparent or translucent region with one or more different materials inlaid within, such as metal, ceramic, wood, quartz, real or synthetic gemstones, mother-of-pearl, leather, etc. Although referred to herein as "transparent," the window may scatter and diffuse light sufficiently that objects viewed through the window are not completely clear. The window alone is more transparent than the combination of the window and backing layer (and any layers above the window). The window insert material can be selected to fall somewhere between translucent (objects viewed through the window are not clearly visible) and transparent (objects viewed through the window are clearly visible). At a minimum, the window is translucent to the light spectrum visible to the general human eye (i.e., wavelengths between approximately 390 and 700 nm; and frequencies within the range of approximately 430 to 770 THz). In preferred embodiments, the window is not tinted. Thus, for example, when stacked in a cardholder's wallet, the window may allow the user to see the cards directly below it with some clarity.

[0019] In some embodiments, it may be desirable for the window to be electrically conductive or have conductive features. For example, in some embodiments, the window may comprise glass coated with a conductive coating, such as an indium tin oxide coating or a conductive ink, or another non-conductive material, such as a plastic resin. In other embodiments, the window may comprise, in whole or in part, a conductive plastic (i.e., polycarbonate or another plastic material formed from a conductive plastic resin).

[0020] 3-6, in some embodiments, the card 300, 400, 500, 600 can have an electronic component 310, 410, 510, 610, such as an integrated circuit, LED inlay, switch, or any electronic feature known in the art, embedded within the window 320, 420, 520, 620 with “invisible” traces 330, 430, 530, 630 comprising ITO or other printed conductive ink or adhesive that can connect the electronic component to an electrical connection 340, 440, 540 at the periphery of the hole and in the interface region between the window and the body 350, 450, 550. In some embodiments, the electrical connection 340, 440, 550 can then be connected to a power source 360, 460, 560, such as a battery or antenna for harvesting RF power. Thus, for example, an LED display can be bonded to or embedded within the window and connected at connection points on the edge of the window with ITO or other printed traces, e.g., to show a dynamic code or to emit light to provide an indicator of the card's operability (e.g., illuminated when information is being actively read from the card). Electronic components can be bonded to the window using conductive adhesive either entirely or only in the areas requiring conductivity, and / or using non-conductive adhesive either entirely or only in the areas intended to be non-conductive. The use of printed conductive traces using transparent, semi-transparent, or minimally visible thin conductive material allows for the integration of electronic components within the window without unsightly wires or copper traces that are immediately visible.

[0021] In embodiments with electrically powered features in the window where power is provided to the features from a power source embedded in the body, as depicted in Figures 3-5, the power source can be connected to the features by inductive coupling or physical traces, with the physical traces in the body connecting to the physical traces in the window across a conductive interface that bridges any gap between the window and the body. The conductive interface 335, 435, 535 can include, for example, solder, wire bonding, conductive ink, or conductive adhesive (e.g., a conductive adhesive patch or ACF tape). The conductive interface 335, 435, 535 and any traces 340, 440, 540 embedded in the metal body 350, 450, 550 are insulated from the metal body by any insulating material and insulating placement method known in the art. For example, as known in the art, the traces 340, 440, 540 can include copper traces disposed on a flexible, non-conductive substrate disposed in a groove in the body. The conductive interface may simply include the connecting end points of the connecting traces (e.g., 330 and 340), or may be somewhat larger than the connecting traces to facilitate alignment when the window is inserted into the hole. It may be highly effective to apply the conductive interface 335, 435, 535 in the form of a solder bump that is applied to bridge the gap between the traces 330, 430, 530 in the window and the traces 340, 440, 540 in the card after the window is inserted. To facilitate alignment of the electrical connections, the holes and corresponding inserts may be non-round or may be secured using a protrusion in the window that mates with a recess in the hole (or vice versa), or the like, so that the insert fits into the hole in only one or a limited number of easily differentiated orientations.

[0022] In the embodiment depicted in FIG. 6 , electronic feature 610 located within window 620 may be entirely powered by inductively coupling RF from the card reader, and antenna 630 is also located within the card and connected to the electronic feature without the need for connection to a power source embedded within body 650. Thus, for example, here electronic feature 610 is a lighting feature that is activated when the card is read, and antenna 630 couples enough electricity to power the light without requiring a connection to any other features embedded within the card. In other configurations, electronic feature 610 and / or antenna 630 may be located on the surface of the card rather than embedded. In other embodiments, electronic feature 610 and / or antenna 630 may be inductively coupled (or physically connected by connections similar to those depicted in FIGS. 3-5 ) to features embedded within the body, such as a power source, or, for example, if the electronic feature is a dual-interface chip, to contacts (e.g., contacts 160 depicted in FIG. 1 ) for reading by a contact reader.

[0023] Window Pattern Embodiments In another embodiment of the present invention, a transaction card may include multiple openings within the obverse side of the card, as depicted in FIGS. 7-17. Specifically, as shown in FIG. 10A, multiple window openings 1010 within card body 1000 form a geometric graphic pattern in the shape of a sphere. As shown in FIG. 10B, multiple window openings 1022, 1024, and 1032 within card 1020 collectively form a stylized Q-shaped alphanumeric character associated with a particular brand of card. As shown in FIG. 10C, each of multiple window openings 1052 includes alphanumeric characters arranged together such that the window openings spell out a word associated with a particular brand of card. The openings are depicted generically in FIGS. 7-9 as a group of distinct ellipses; in cross-section in FIGS. 11-15, these openings have no discernible geometric shape. The pattern, shape, size, and number of the openings are not limited in any way. The openings may form a recognizable or abstract pattern. The openings are preferably merely aesthetic in nature and do not serve any function other than to create a suitable pattern or design, which may be user selectable and selected to be difficult to reproduce. Thus, while the pattern or design may passively enhance the security of the card in that its very presence provides a mark of authenticity that is difficult to reproduce, the preferred pattern or design is referred to herein as "non-functional" in that it does not have any active or interactive functionality.

[0024] As depicted in Figures 7-9, card body 700 has multiple window openings 702, 704, and 706 extending through the front side of the card body. While referred to here and in the claims below as the "front" side, the term "front" as used herein with respect to this and other embodiments refers to the side of the card on which the window openings are located, which may be the side traditionally referred to as the "front" or "back" side of a functional card, with magnetic strips, contacts, and other indicia that may generally be understood to differentiate between the "front" and "back" sides of a card. While each opening has a different perimeter visible from the front side of the card, all of the windows are positioned within the area defined by pocket 804, depicted in Figure 8, which defines a single opening in the back side of the card. Insert 800 is configured to be placed within pocket 804. As depicted in Figures 8, 9 and 12, card body 700 has a recessed shelf 802 in its rear side surrounding a single opening 804, and insert 800 includes a stepped periphery including an outermost region 902 having a geometry configured to mate with the recessed shelf and an innermost region 904 configured to fit within the single opening.

[0025] In another embodiment depicted in FIG. 11 , the body can include at least two layers, including a first layer 1100 defining the front side 1150 of the body and a second portion 1102 defining the back side 1152 of the body. Multiple openings 1110a, 1110b, and 1110c extend through the entire thickness of layer 1100, while a single opening 1120 extends through the entire thickness of layer 1102. An insert 1104 is configured to fit within opening 1120, which defines a pocket when layers 1100 and 1102 are combined together. While not shown, a recessed shelf in layer 1102 and a corresponding perimeter region on insert 1104 can be present in this embodiment as well. While depicted in FIG. 11 as having the same thickness, the two layers 1100 and 1102 can have different thicknesses, with either layer being thicker than the other. The layers can be adhesively bonded together. There may be additional layers as well, including a transparent or semi-transparent bonding layer between layers 1100 and 1102 that fills the plurality of openings 1110a-1110c during the lamination step. A backing layer 1106 may be laminated or otherwise bonded to the backside of layer 1102 to hold insert 1104 in place.

[0026] As shown in FIG. 11 , the insert can consist of the member 1104 alone. In some embodiments, the member 1104 and backing layer 1106 (and any intermediate or top layers) can be transparent or translucent, allowing light to be seen through the openings 1110a-1110c. However, in preferred embodiments, the insert 1104 includes a non-transparent member selected for aesthetic impact. For example, the insert 1104 can include plastic, metal (e.g., having visual properties different from any visible metal within the body), ceramic (e.g., having visual properties different from any ceramic or ceramic coating comprising the body), wood, quartz, mother-of-pearl, stone (including artificial or natural gemstones), natural or synthetic bone or ivory, and natural or synthetic leather. Any of the above can have printing thereon (e.g., a printed plastic insert with a graphic that allows visibility to different colors through different openings). Typically, the non-transparent member is opaque, but in other embodiments, it can have some translucency. Member 1106 can have printing on one or both sides, and in some embodiments includes printing visible from one surface of the card that is different from printing visible from the opposing surface of the card.

[0027] Typically, member 1104 is passive and static, but may also be dynamic, such as a photoluminescent (e.g., glowing in the dark or fluorescing when illuminated by light of a certain wavelength). Member 1104 may also be a light source, such as an LED, or more specifically, a backlight LED connected to a light source (not shown) in the same manner as described herein for other elements connected to a light source. In yet another embodiment, member 1104 may be a light guide that receives input light from a light source, such as an LED or backlight LED (not shown), at an input surface of the light guide and transmits light to an output surface. The light may cooperate with a window to create an illuminated pattern to indicate, for example, a payment module read, but is not limited to any particular purpose.

[0028] In yet another embodiment, member 1104 may include an OLED (organic light-emitting diode). The use of OLED components in transaction cards is generally described, for example, in U.S. Patent No. 6,277,949, entitled "Organic Light-Emitting Diode ("OLED") General Purpose Plastic," and U.S. Patent No. 6,277,949, entitled "Flexible OLED Card," both of which are incorporated herein by reference. While the referenced disclosures describe the use of OLED technology in connection with flexible plastic cards, it should be understood that the general techniques for providing OLED displays are available for incorporating OLED displays into relatively non-flexible or flexible card structures. However, the flexibility of OLED displays can be extremely useful in conjunction with an overall card structure having enhanced flexibility (e.g., flexibility exceeding ISO / IEC 7810 ID-1 standards for transaction cards and meeting or exceeding ISO / IEC 15457 standards for thin flexible cards). Flexible card structures using OLED displays may further include flexible circuit boards. Thus, the term "LED" as used herein in connection with displays should be construed to mean either OLED or non-organic LED.

[0029] In other embodiments, member 1104 may be a dynamic or kinetic member, such as that described in U.S. Provisional Patent Application No. 62 / 545,630, entitled "Card with Dynamic Shape Memory Alloy Tactile Features," which is incorporated herein by reference. Member 1104 may differ from the main body in any number of respects, including its color, texture, reflectivity, opacity, and combinations thereof. Member 1104 may include a display and a processor configured to generate a dynamic security code on the display, such as those described in U.S. Patent Application No. 16 / 124,711. Any or all of the electronic components described herein may be embedded within the card in any manner known in the art, including U.S. Patent Application No. 16 / 124,711, entitled "Overmolded Electronic Component for Transaction Card and Method of Manufacturing Thereof," filed October 18, 2018, which claims priority from U.S. Patent Application No. 16 / 320,597, filed January 25, 2019, or the method described in U.S. Patent Application No. 16 / 124,711.

[0030] 12, the insert may consist of only a single member 800 such that, when the card is assembled, the entire obverse-facing surface of the member is recessed relative to the obverse side of the body, i.e., multiple windows 702-706 are tactilely perceptible within the obverse side of the card. Thus, for example, if insert 800 includes mother-of-pearl, lamination of the card does not alter this physical relationship between the components. Although not transparent, member 800 may be transparent in some embodiments.

[0031] However, in other embodiments, as depicted in FIG. 13, the insert 1302 can include a material that is flowable at the lamination temperature and that can flow partially or completely into the multiple openings in the body 1300 during the lamination step, such that multiple portions 1304, 1306, 1308 of the front-facing surface of the non-transparent member protrude into the multiple openings and are positioned flush with the front side of the body.

[0032] 14, the entire front-facing surface of the non-transparent member 1402 may remain recessed relative to the front side of the body, and multiple transparent or translucent members 1404, 1406, 1408 may be placed within the openings. The transparent or translucent members may include optically clear epoxy that is applied via automated dispensing into the openings.

[0033] In yet another embodiment depicted in FIG. 15, a transparent or translucent layer 1510 may be disposed over the entire front surface of the body 1500 and over a plurality of openings, such that protrusions 1504, 1506, and 1508 from the layer flow fully or partially into the openings during the lamination step, while the layer 1502 remains generally recessed relative to the front surface of the body.

[0034] As depicted in FIG. 16, in a multi-layer body structure, an intermediate transparent or semi-transparent bonding layer 1610 can be disposed between the first layer 1500 and the second layer 1502 of the body, such that the protrusions 1604, 1606, and 1608 flow completely or partially into the openings during the lamination step, while the layer 1620 remains generally recessed relative to the front side of the body.

[0035] As depicted in FIG. 17 , transparent or translucent layers 1702 and 1704, respectively, disposed across the front and back sides of body 1700, flow completely or partially into openings 1710 and 1712 during the lamination step. This structure and manufacturing method is highly suitable for embodiments in which openings 1710 and 1712 are slits, such as window features 1022, 1024, 1032, and 1052 depicted in FIGS. 10B and 10C . While shown with upper and lower layers, some embodiments may have only one or the other. While shown with a single, discrete upper layer and a single, discrete lower layer, some embodiments may have multiple layers above and / or below the body, and in some of these embodiments, two or more layers may contribute to filling the openings. For example, an adhesive layer, which may include a carrier with adhesive on both sides, may be interposed between the body and each of the upper and / or lower layers, and the adhesive, carrier, and upper or lower layer may all flow into the openings during the lamination step. In other embodiments, the adhesive on the underside of the carrier (or disposed directly on the underside of the top and / or bottom layers) may be the only material that flows into the openings.

[0036] Although shown with coplanar surfaces in Figure 17, it should be understood that the material flow can lead to convex, concave, coplanar, or irregularly shaped surfaces of the flowing material on one or both sides of the card. The formation of convex, concave, coplanar, or irregularly shaped surfaces can occur in any embodiment where material flows into a window / groove / pocket, and the overall shape can be intentionally controlled to have a specific shape. Similarly, in embodiments where the insert is preformed and assembled into the window / groove / pocket, the insert can similarly conform to any of these shapes.

[0037] Although FIGS. 13-17 all depict monolithic bodies, it should be understood that the bodies in these embodiments may include multi-layer bodies such as those depicted in FIG.

[0038] 12, a method and process for manufacturing a card with a window pattern may include providing a metal, ceramic, or ceramic-coated body 700, creating a pocket 804 having a periphery and extending from the back side to a location adjacent the front side, and then creating a plurality of openings 702, 704, 706 extending from the front side into the pocket, the plurality of openings forming a pattern. An insert 804 is positioned in the pocket, after which a non-metallic backing layer 1206 adjacent the back side of the body and the back side of the insert are laminated to the body and insert.

[0039] In some embodiments, such as that depicted in FIG. 11 , providing a body can include providing a first layer 1100 defining a front side of the body and a second layer 1102 defining a back side of the body. In such embodiments, creating a pocket can include creating a through-hole 1120 in the second layer 1102, and creating a plurality of openings can include creating a plurality of through-holes 1110a-c in the first layer 1100. The openings, pockets, and through-holes referred to in these processes can be laser cut, milled, etched, or machined by any method known in the art. For ceramic-coated embodiments, a body or body layer of metal or other material can first be coated with ceramic, after which the various openings are cut and the layers are assembled; or, openings and / or layers can be cut in a metal or other body first, after which a ceramic coating can be applied to the exterior surface before the remaining components are assembled.

[0040] As depicted in FIG. 12 , the process can include creating a recessed shelf 802 in the back side of the body surrounding a pocket 804, and forming an insert 800 with a stepped periphery including an outermost region 902 having a geometry configured to mate with the recessed shelf 802 and an innermost periphery 904 configured to fit within the pocket 804.

[0041] Positioning the insert within the pocket may include bonding the outermost region of the insert to a recessed ledge within the body, for example, with an adhesive or via non-adhesive mechanical bonding, such as ultrasonic welding, brazing, or soldering. Using a recessed ledge design in conjunction with a bonding material, such as an adhesive, solder, or brazing alloy, allows for bonding onto the ledge in a manner that minimizes the flow of adhesive or other bonding material into the openings in the front surface of the body. However, in other embodiments, it may be desirable for a bonding material, such as a cured, dry, clear epoxy, to flow into and fill the openings, creating a transparent window, as depicted in FIG. 14 , in which case no ledge may be desired. Other methods of filling the multiple openings with clear epoxy may include automatically dispensing the epoxy into the openings after the inserts are already in place. Yet another method of filling the openings with a transparent or translucent material may include disposing a transparent or translucent coating over the entire front surface of the body (e.g., via lamination of a solid layer or by spray coating or application of a liquid layer) and at least partially filling the multiple openings with a portion of the transparent coating that flows into the multiple openings, e.g., during the lamination step.

[0042] As noted above, in embodiments in which the insert includes a material that is flowable during lamination, the process can include performing the lamination step with sufficient heat and pressure to cause protrusions from the insert to flow completely or partially into the plurality of openings during the lamination step. In embodiments involving slits, such as those depicted in Figures 10B, 10C, and 17, the openings can be etched, milled, or created by a laser (but is not limited to any particular formation method).

[0043] As depicted in FIG. 10B , for ease of manufacturing, creating the slit 1032 may include creating a continuous slit defined by portions 1030 and 1032, extending from the payment module pocket 1034 to the edge of the card. If portions of the slit, such as portion 1030, are not desired to be transparent or translucent for aesthetic reasons, such portions may be filled with a different type of filler, such as a non-conductive filler that is not transparent or translucent. Such a filling step would occur before the lamination step of filling the transparent or translucent window portion. The continuous slit defined by portions 1030 and 1032, with portion 1030 filled with a non-conductive filler that matches the card and portion 1032 filled with a non-conductive transparent filler, can be operated to allow the metal frame 1020 to function as an amplification antenna or a coupling frame, as disclosed in U.S. Patent Application No. 15 / 928,813, the entirety of which is incorporated herein by reference. As shown in FIG. 10C, in other embodiments, the slit 1056 starting from the module pocket 1054 in the card 1050 may be a separate element that is not integrated into the manufacture of the design defined by the transparent or translucent window 1052.

[0044] It should be understood that creating an extended opening as depicted in FIG. 10B and filling one portion with a transparent or translucent filler material and another portion with a non-transparent / non-translucent filler material is not limited to embodiments in which the slit as a whole connects the payment module pocket to the edge of the card. For example, for ease of manufacturing, it may be desirable to create a continuous slit and then fill multiple portions of the slit with different filler materials for purely aesthetic reasons, and the different filler materials can be of any type. For example, the filler material can be transparent, translucent, opaque, conductive, non-conductive, or any combination thereof, and different sections of the same continuous opening (or different individual openings) have different filler materials, each filler material having a different aesthetic appearance, such as a different color, different texture, etc. If desired, the filler material can include a precious metal such as gold. In other cases, the window or portions thereof may be illuminated, such as using LEDs as described herein. The "filler material" (and insert material) can fully or partially fill all or some of the openings in any of the embodiments disclosed herein.

[0045] In one embodiment depicted in FIG. 18 , a light guide layer 1825 containing a light guide 1810 and a light source 1815, such as a backlight LED, may be sandwiched between metal layers 1820 and 1830. The LED 1815 is positioned adjacent the input end to the light guide, and windows 1802, 1804, and 1806 are positioned adjacent the output surface of the light guide. Light from the LED 1815 enters the light guide and is transmitted out through windows 1802, 1804, and 1806. While depicted in one embodiment in FIG. 18 , it should be understood that embodiments with light guides positioned below openings in the metal layer can be provided in any of the other configurations described herein. The windows 1802, 1804, and 1806 may be free of filler or transparent or translucent filler material and may be formed via any of the methods described herein or conform to any of the structures described herein.

[0046] In some embodiments or designs, rather than creating a continuous slit, such as the circular shape formed by slits 1022 and 1024, it may be more desirable for the overall structural stability of the card to create separated slits with one or more metal bridges 1026, 1028. As depicted in FIG. 10B, without bridges 1026 and 1028, the central circular portion would be completely separated from the remainder of the metal body. However, providing a metal separation between adjacent slits is not limited to only those embodiments that would prevent separation.

[0047] As used herein, the term "slit" refers to a gap formed between metal edges, where the distance between the edges is small enough that it is undesirable or impractical to place a separate filler material into the slit prior to the lamination step, minimizing the risk of air bubble formation during lamination. Lamination conditions can be controlled as desired so that the slit is filled by the overlying and underlying layers without leaving a noticeable depression, or is partially filled to provide a tactilely noticeable depression.

[0048] Other Card Features In embodiments where the card body is metal or ceramic-coated metal and the transaction card includes a payment module configured for "contactless" interfacing with a card reader (e.g., where, in at least one mode of operation, transaction circuitry embedded within the card inductively couples to a card reader using RFID technology), positioning a window adjacent to the module can enhance the card's RF performance and thus extend the distance at which the card can be read in contactless mode. Specifically, the absence of metal adjacent to the module, particularly near the module antenna, can significantly improve (extend) the read distance between the card and the card reader required to couple the card to the card reader, compared to a card without a transparent window. The optimal distance can be determined by creating multiple otherwise identical cards with different window sizes and locations and testing the read distance difference for different designs. Generally, applicants have found percentage read distance improvements in the range of 12-50%, depending on the distance between the edge of the metal card and the module, within the range of 1-5 cm. Therefore, the absence of significant metal areas within this 1-4 cm distance due to holes in the metal body to accommodate the window is expected to provide a measurable level of improvement. Because dual interface devices operate in both "contactless" and "contact" modes, it should be understood that references to devices having "contactless" functionality encompass both modules having only contactless functionality as well as modules having dual interface functionality.

[0049] In some embodiments, the payment module may be positioned inside a transparent window, in which case the coupling antenna may be positioned surrounding the module with traces that are minimally visible inside the transparent window. In other embodiments, the entire metal card body can be used as the coupling antenna, or the coupling antenna can be embedded within the body as is known in the art. The minimally visible traces, including the antenna traces, and the module may be obscured or integrated into graphic content similar to a printed design on the window. However, the positioning of the card reader module inside the window is not limited to metal or ceramic-coated metal embodiments, but may also be present in embodiments featuring an all-ceramic or ceramic-coated non-metallic body.

[0050] As shown in FIG. 3 , electronic components 310 and optional connecting traces 330 can be disposed on a surface of the window, preferably on the back surface of the window, and the electronic components can be further covered or protected by a backing layer. In alternative embodiments, as shown in FIGS. 4 and 5 , electronic components 410, 510 can be embedded within windows 420, 520. In one embodiment depicted in FIG. 5 , the embedded electronic components can be embedded by injection molding electronic components 510 within the transparent or translucent polymer that makes up window 520. In such embodiments, one or more conductive members 532 connected to the electronic components can be disposed within the window oriented along the thickness of the window (perpendicular to the front and back surfaces of the window) to transmit power and / or signals from the interior portion of the window to the window surface 522 (or a layer closer to the window surface), with the conductive members 532 connecting to conductive traces 530 printed on the window. An exemplary process for embedding electronic components for insertion into a metal card body is described in U.S. Provisional Patent Application No. 62 / 555,367, entitled "Transaction Card with Embedded Electronic Components and Method of Manufacturing Same," which is incorporated herein by reference.

[0051] In another embodiment depicted in Figure 4, electronic components may be disposed on a first layer 422 of an optional transparent or translucent polymer, upon which a second layer 424 is disposed to encapsulate the electronic components (and optionally one or more conductive traces 430 for connecting to the electronic components). A multi-layer window is not limited to only two layers and may include any number of layers that may provide desired aesthetic or functional qualities. In a multi-layer embodiment, the conductive traces 430 may be printed on the first layer 422 before another layer (e.g., 424) is disposed.

[0052] A non-metallic backing layer 120 (e.g., clear PVC, but not limited to any particular construction material), which is relatively thin compared to the relatively thick base, is preferably laminated to the back side of the body and the back side of the window. While not limited to any particular thickness range, transaction cards are generally standardized in size at approximately 0.032 inch (0.81 mm) thick, with the body typically being in the range of 0.008-0.028 inch (0.20-0.71 mm), preferably 0.010-0.020 inch (0.25-0.51 mm), and more preferably 0.012-0.018 inch (0.30-0.46 mm), and the backing layer optionally having a thickness to make up the difference between the total thickness and the body, minus the thickness of any adhesive layers or other coatings.

[0053] One or more features can be printed on the body, which may include a printable metal such as printable stainless steel (e.g., stainless steel having a coating (not shown) on at least the front surface 104 that improves acceptance of printing ink on the steel surface). The coating may include, for example, a polyester-based coating that is receptive to UV-cured screen and inkjet inks or solvent or oxidation printing. In other embodiments, dye or dye-sublimation printing can be used. In embodiments involving ceramic or ceramic-coated bodies, the ceramic may similarly be coated and roughened (e.g., chemically, mechanically, or with a laser) to accept the printed layer. Printed embodiments are not limited to any particular printing technology or technique.

[0054] As depicted in FIG. 1A , the front side of the card can have a decorative pattern. The decorative pattern can be a printed pattern (or, as described further below, can be an engraved or etched pattern), or the front side can be printed in a solid color (e.g., black as shown in FIG. 1A ) or can include any combination of a solid color, a printed graphic or pattern, printed information, and an engraved or etched pattern, graphic, or information. The printed information can include the name of the card issuer (e.g., Citi, Bank of America, etc., represented by the text "BANK" in FIG. 1A ), the card type and / or name (e.g., VISA® SAPPHIRE, AMERICAN EXPRESS®, etc., represented by the text "CARDNAME" in FIG. 1A ), the cardholder's name, the card's unique serial number, an expiration date, etc. Some printed information (graphics, card name, etc.) can be printed in a first printing step to create a card "blank" ready for personalization, while other printed information (cardholder, serial number, expiration date) can be printed in a second, personalized printing step. The first and second printing steps are typically geographically and temporally separated from one another and performed by different printers. Printing extends to printing on the window insert, including printing across the border area between the window periphery and the hole periphery. Printing can be performed using UV-curable ink, although the invention is not limited to any particular type of ink.

[0055] The front surface of the body may further have decorative grooves disposed therein, e.g., etched, machined, lasered, etc. Thus, in one embodiment, the pattern shown in FIG. 1A may consist of a solid black print base with grooves arranged in a pattern (depicted in FIG. 1A as a fish scale pattern, but not limited to any particular type of pattern, and not limited to a repeating or regular pattern, a single pattern, or a pattern having any particular amount of coverage—i.e., the pattern may extend across the entire face of the card or may be limited to one or more clearly distinct areas of the card). The grooves may be filled with an ink of a different color than the face of the card, or the grooves may expose the color of the metal or ceramic, or the color of the body underlying the ceramic below the printed layer. The grooves may penetrate only the printed layer, or may penetrate the body. The grooves may be cut into a window and extend across the boundary area between the edge of the body and the window. Similarly, the printed layer on the card may extend across this boundary area.

[0056] 1A , the border area 132 between the respective perimeters of the window insert 112 and the hole 108 is positioned radially within a printed feature, such as a printed solid black circle 130 surrounding the boat graphic 118, such that the printing extending across the entire border area helps to visually reduce the border area's prominence. In another embodiment, the border area may be positioned slightly radially outward from the circle 130, such that the design imparted by the groove similarly extends across the border area, further reducing its prominence. In embodiments in which a window substantially free of printing is desired, the printed content may include only a decorative peripheral outline that overlaps the border area (i.e., is disposed on both the window and the card body on either side of the border area), such that a large portion of the window positioned radially inward of the border area or the printed peripheral outline is free of printing.

[0057] In some embodiments, the obverse side may further include an optional hard coating layer 140, while other embodiments may have no coating at all over the printed / engraved layer or over the uncoated metal or ceramic surface on the obverse side of the card. The transaction card may further include a magnetic stripe 150, a signature panel 152, a hologram 154, a machine-readable code 156 (depicted as a barcode, but which may include any type of machine-readable code, including, but not limited to, a QR code), or a combination thereof, preferably disposed on the backing layer 120 over the entire back side 106 of the body 102. Most embodiments also include an embedded integrated circuit (not shown), an embedded RFID antenna (not shown), or a combination thereof (for dual interface (DI) cards) connected to contacts 160 configured to be read by a card reader to enable use with contact and / or contactless card readers. While the hole 108 may be purely cosmetic in nature, it may be advantageous to position the hole on the card in a location that enhances the RF performance of dual interface cards.

[0058] An exemplary process for manufacturing the transaction cards described herein may include first providing a body 102 having a thickness (T) and creating a hole 108 in the body having a periphery and extending from the front side 104 to the back side 106 of the body. A non-metallic backing layer 120 is affixed in place, preferably with an adhesive disposed on the side of the backing layer facing the body, and positioned adjacent the back side of the body, a non-magnifying transparent insert 112 is inserted into the hole 108 in contact with the adhesive of the backing layer 120, and the assembly is then laminated together. The inserts may be made by any method known in the art, such as by cutting or punching multiple inserts having the desired periphery from a sheet of insert material, or by extruding a rod having the insert periphery and cutting chips having the thickness (T) from the rod.

[0059] The holes 108 can be created by any method known in the art, such as by cutting (e.g., mechanical or laser cutting), punching, or etching into the metal body using, for example, a computer-controlled (e.g., computer numerically controlled, or CNC) machine. In embodiments in which the body comprises printable stainless steel (or any other coated metal where coating integrity is important), a resist can be applied over the entire coated surface or portions thereof that are desired to remain coated during any acid etching step (e.g., if an etching step is used to create holes). For example, the resist is applied to the entire surface of the metal except where the holes 108 and any other pockets or surface patterns are to be formed. After etching, the remaining resist is removed, and the body is ready for further processing.

[0060] In exemplary ceramic body embodiments in which the body comprises a solid ceramic, holes are preferably formed in the ceramic's green state, after which the ceramic is fired. The size of the hole diameter before firing is selected to produce the desired fired hole diameter given the ceramic material's properties and the expected change in hole diameter, if any, during the firing process. Alternative processes include producing a ceramic blank without holes and then mechanically milling, laser machining, or freeze / fracturing the holes after firing, but such methods are generally less efficient and therefore not preferred. In exemplary embodiments in which the body comprises a metal core with a ceramic coating, the metal body can be fabricated as described above, after which the desired ceramic coating is applied over the metal. For example, a spray coating of ceramic combined with a binder can be applied, or the ceramic can be placed around the metal, for example, by injection molding, and then fired. In preferred embodiments, the sprayed ceramic coating can be applied only to the front surface of the metal core. Ceramic-coated bodies with non-metallic cores can be processed in a similar manner.

[0061] The laminated assembly is then subjected to a printing step to print what is desired on the front surface of the body. In an exemplary process, the printing step involves printing the print with an inkjet printer using UV-curable ink, followed by exposing the print to ultraviolet radiation suitable for curing the ink. Grooves may be etched or engraved into the front surface of the body before or after printing. In a process for filling the grooves with inks of different colors, metals, etc., a groove filling step can be performed after the grooves are created, for example, by a wiping step in which the filler material (ink, metal, resin, etc.) is wiped off the surface so that only the filler material (ink, metal, resin, etc.) is deposited in the depressions created by the grooves.

[0062] Although described above in a preferred order of steps, the foregoing steps are not limited to being performed in any particular sequence. For example, in some processes, the steps of cutting holes, applying a backing layer in place, and inserting windows may occur after steps related to printing on the front side of the card, creating grooves, etc. In other processes, the grooves can be created before printing.

[0063] As depicted in FIG. 2 , each completed transaction card 100 defines a first bounded area (corresponding to the length and width of the card minus the area of any rounded edges). In metal card embodiments, the cards may be manufactured from a sheet 200 having a second area that is somewhat larger than a multiple of the first area (e.g., slightly larger than eight times as depicted in FIG. 2 ). In such manufacturing processes, the process further includes cutting the metal sheet into a plurality of transaction cards corresponding to this multiple. As depicted in FIG. 2 , the ratio of the second area to the first area is generally not an integer (e.g., something between 8 and 9 as depicted in FIG. 2 ), while the multiple corresponding to the number of cards to be cut from the sheet may be rounded down to the nearest integer corresponding to the second area. The cutting steps to cut holes and to cut individual cards from the sheet may be performed with a laser. Any grooves may be machined, etched, or laser formed. Although depicted in FIG. 2 as a nearly finished card, it should be understood that in some embodiments, the metal or other material core may similarly be cut from a larger sheet prior to application of the ceramic coating.

[0064] The integrated circuit and connected contacts and / or antenna may be embedded within the metal card by any method known in the art, such as described in U.S. Patent Application Publication No. 2007 / 0129994, which is incorporated herein by reference. In embodiments in which an optional hard cover layer is applied to the obverse side of the card, the hard cover can be applied as a separate layer or as a coating, such as described in U.S. Patent Application Publication No. 2007 / 0129994, which is also incorporated herein by reference for its teachings of applying hard cover layers to metal cards. Although described herein with reference to only certain layers, it should be understood that some embodiments can include additional layers between, above, or below the described layers, including, but not limited to, laminates, adhesive layers, printed content, or coatings (including, but not limited to, ceramic coatings).

[0065] 19A-19C, another transaction card embodiment 1900 is illustrated. The transaction card includes a metal layer 1910 having a front surface and a back surface and at least two openings 1920 and 1930, each extending through one or both of the front and back surfaces of the metal layer. In the embodiment depicted in FIG. 19B, openings 1920 and 1930 both extend through both the top and bottom surfaces of the metal layer, with opening 1920 having a relatively larger perimeter at the top surface than at the bottom surface. A transponder module 1925 (preferably contactless or dual interface) may be disposed within opening 1920 and rest on a step 1921 between the relatively wide and relatively narrow portions of opening 1920. The transponder module 1925 may be disposed on or within a plug of non-metallic material, as is known in the art.

[0066] An LED module 1935 is disposed within the opening 1930. The LED module 1935 has a planar illumination area 1937 visible from the finished surface (e.g., the obverse surface) of the transaction card. As depicted in FIG. 19C , in one embodiment, the LED module 1935 includes LEDs 1932 configured to emit light and a light guide 1933 for distributing light emitted by one or more LEDs throughout the illumination area 1937. Some portions of the LED module 1934 may thus be unilluminated. The unilluminated portions may thus be hidden behind opaque areas of an upper layer or printing thereon, and features of the upper layer or printing thereon may be optimized to print across the boundary area between the illuminated portion 1937 of the LED module and the periphery of the opening 1930. As depicted in Figure 19B, the LED module is secured within a window 1930 that penetrates completely through the metal layer from top to bottom, such that the bottom surface of the LED module is flush with the bottom surface of the metal layer and the top surface of the LED module is flush with the top surface of the metal layer. In other embodiments, the LED module may be secured within a blind pocket that does not penetrate completely through the metal layer from top to bottom. Typically, the LED module, and particularly the illumination area 1950, is non-transparent or non-translucent, so that anything located behind the LED module (e.g., the backing layer 1940 or the bottom of the blind pocket) is not visible from the front side of the card.

[0067] Any number of LEDs 1932 can be provided. In some embodiments, a lighting circuit for the LEDs can include at least two LEDs, with more or different LEDs illuminating as indicators of field strength (e.g., greater field strength leads to greater harvested energy and therefore more power available to the lighting circuit, which can illuminate in various power-dependent ways). In some embodiments, all LEDs (e.g., 1932a, 1932b) can be the same color, and the circuit is configured to illuminate only the first LED at a minimum field strength and illuminate both the first and second LEDs at a relatively higher field strength. In a circuit (not shown) with more than two such LEDs, the first, second, and third LEDs can all illuminate at a relatively highest field strength. Thus, the energy range over which the first LED illuminates overlaps with the entire energy range of the second LED. In a configuration with three LEDs, the energy range over which the first LED illuminates overlaps with the entire energy range over which each of the second and third LEDs illuminate, and the energy range over which the second LED illuminates overlaps with the entire energy range over which the third LED illuminates.

[0068] In other embodiments, multiple colored LEDs can be provided, with the circuitry configured to illuminate a first LED 1932a (e.g., red) corresponding to a relatively weak field strength and a second LED 1932b (e.g., green) corresponding to a relatively strong field strength. The ranges in which the two different LEDs illuminate can have overlapping ranges. For example, two sets of LEDs can be configured to illuminate the red LED 1932a within a first output range (e.g., 1-66%) and the green LED 1932b within a second output range (e.g., 33-100%), with both LEDs illuminating to produce yellow light within the overlapping range (e.g., 33-66%).

[0069] The intensity of illumination can similarly vary based on field strength, such that multiple LEDs or a single LED having the same wavelength can provide varying brightness as a field strength indicator. For example, in an embodiment in which both LEDs 1932a and 1932b emit the same wavelength, the illumination intensity of LED 1932a can range from a relatively low intensity at 1% field strength to a relatively high intensity at 50-100% field strength, and the illumination intensity of LED 1932b can range from a relatively low intensity at 51% field strength to a relatively high intensity at 100% field strength. Similarly, multiple LEDs having different wavelengths can be illuminated in various combinations of one or more LEDs to create a spectrum of colors based on field strength. For example, from the relatively weakest to the relatively strongest field strength, the LEDs can be illuminated within a spectrum (e.g., red = red LED only, optionally throughout the range from relatively dim to relatively bright intensity; orange = red LED intensity more than green LED intensity; yellow = relatively equal red and green LED intensity; yellow-green = green LED intensity more than red LED intensity; green = green LED only, optionally throughout the range from relatively dim to relatively bright intensity). The number and / or color of LEDs are not limited to any particular configuration. Those skilled in the art of electronics will be familiar with the basic circuitry required to illuminate different LEDs in response to power supplied to the circuit, and therefore specific configurations will not be detailed herein. The ranges and variations throughout these ranges are merely exemplary and are not intended to limit the invention in any way.

[0070] As will be appreciated by those skilled in the art, in use, the contactless or dual interface transponder module is a component in a transaction circuit configured to communicate with a card reader (not shown) configured to emit radio frequency (RF) waves having energy. As is well known in the art, the transaction circuit includes a transponder module 1925 configured to receive (using a receiver connected to antenna 1986) an input RF signal 1984 emitted by a transmitter's transmitting antenna 1982 in the card reader 1980, and to respond with an output RF signal 1985 emitted by the transmitter using a transmitting antenna 1988 and received by the receiver using the card reader's receiving antenna 1983. The receiver / receiving antenna 1982 and the transmitter / transmitting antenna 1983 may comprise a single transceiver / transmitter / receiver antenna configured for two-way communication. The transponder is typically powered by harvesting energy from the RF waves 1984 emitted by the card reader 1980. The transponder typically has its own power generation circuitry similar to that described below in connection with the power supply for the LED module. In other embodiments, power may be provided by an actively powered RF transceiver using a power source (e.g., a battery) built into the device, and / or the LED may have a power source built into the device (or share one with the transponder).

[0071] The LED module 1935 includes one or more components in a lighting circuit that is also powered by energy harvested from the RF waves 1984. The lighting circuit includes a power supply 1990 that includes an energy harvesting circuit (configured to generate AC or DC power), LEDs 1932, and one or more surface-mount (SMT) components 1938. For example, the lighting circuit in one or more of the SMT components may include a charge pump (also called a voltage pump or voltage generator) to boost the operating voltage of the lighting circuit above the voltage of the RF waves; this circuitry is generally known to those skilled in the art. Any type of circuitry for boosting or reducing voltage may be provided. In some embodiments, the lighting circuit and the transaction circuit are isolated from each other, such that the lighting circuit is configured to illuminate regardless of the status of a transaction performed by the transaction circuit. As used herein, the term "transaction circuit" refers to any circuitry for processing transactions. In a payment device (credit card, debit card), the transaction circuitry may include a general payment circuitry configured to exchange payment information between a card and a card reader such that the payer's account is ultimately credited and the payee's account is ultimately credited. However, suitable transactions are not limited to payment transactions and may include any information exchange between a card and a card reader that ultimately results in recorded information. For example, a casino loyalty card may track the amount a user has bet, won, or lost; this record is a "transaction" without the loyalty card actually making any payments associated with the bet, winnings, or losses. Therefore, the term "transaction circuitry," as used herein, should be understood to mean any information exchange related to any type of transaction, including, but not limited to, a payment circuitry.In other embodiments, the lighting circuit and the transaction circuit comprise components within an integrated circuit in which the lighting circuit is configured to illuminate in a manner indicative of the status of a transaction performed by the transaction circuit. In yet other embodiments, the transaction circuit and the lighting circuit can both share power from a single energy harvesting source (i.e., the lighting is independent of the status of the transaction) without the transaction circuit and the lighting circuit being otherwise connected to each other.

[0072] An exemplary simple energy harvesting circuit 1900 is depicted schematically in the enlarged region of FIG. 19A and, as is well known in the art, generally includes a receiving antenna 1991 attached to a rectifier / voltage multiplier 1994 for receiving RF waves from a source (in this case, waves 1984 from card reader 1980), a capacitor 1995 (or battery) in parallel with one or more resistors 1992 disposed between antenna 1991 and ground 1993, and generates a direct current (DC) voltage between electrodes 1996 and 1997. This DC voltage powers the connected circuitry. An impedance matching network (IMN) (not shown) between the antenna and the rectifier and / or any other logic or other circuit components known in the art for use in power harvesting applications may also be included in circuit 1900.

[0073] 19A and 19B, metal layer 1910 has a first discontinuity 1902 extending from the periphery of the card to opening 1920 and a second discontinuity 1904 extending from the periphery of the card to opening 1930. Card 1900 further includes a back non-metallic layer 1940 disposed on the back surface of metal layer 1910 and a front non-metallic layer 1950 disposed on the front surface of the metal layer. A pattern 1960, such as a word, logo, or graphic printed or otherwise disposed on or in front non-metallic layer 1950, covers an illuminated area 1937 of the LED module positioned to be backlit by the LED module. For example, although shown in Figure 19B as a raised positive pattern 1960 made from printing ink disposed on layer 1950, the pattern may include opaque portions of the non-metallic layer 1950 itself, in a negative pattern formed by holes in the otherwise opaque non-metallic layer 1950. The pattern may be multicolored. Metallic layer 1910 may act as a booster antenna connected to one of the antennas 1986, 1991 to amplify the signal received from the card reader, or may be isolated from one or both of the payment and / or lighting circuits.

[0074] Locating the opening 1930 and LED module in close proximity to the transponder module 1925 may provide improved RF performance for the card compared to a card in which the window is absent. Similarly, the first and second discontinuities 1902, 1904 also improve RF performance compared to a card in which the discontinuities are absent.

[0075] Although the invention has been illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications of the details may be made within the scope and range of equivalents of the claims without departing from the invention. The following are some aspects of the embodiment of the present invention. [Aspect 1] A transaction card having a facing surface and a periphery, comprising: a metal layer having opposing surfaces and at least two openings, each opening extending through one or both of the opposing surfaces; a transponder module disposed within one of the at least two openings in the metal layer, the transponder module including a component in a transaction circuit configured to wirelessly communicate with a card reader configured to emit radio frequency (RF) waves having energy, the transaction circuit configured to receive an input RF signal from the card reader, respond with an output RF signal, and power the transaction circuit by harvesting energy from the RF waves; an LED module disposed within another of the at least two openings in the metal layer, the LED module having a planar illumination area visible from a finished surface of the transaction card, the LED module including one or more LEDs configured to emit light and including components in an illumination circuit configured to harvest energy from the RF waves to power the one or more LEDs; Including transaction cards. [Aspect 2] 2. The transaction card of claim 1, wherein the illumination circuitry is configured to illuminate regardless of the status of a payment transaction conducted by the transaction circuitry. [Aspect 3] 2. The transaction card of claim 1, wherein the illumination circuit and the transaction circuit constitute components within an integrated circuit in which the illumination circuit is configured to illuminate in a manner indicating the status of a payment transaction being conducted by the transaction circuit. [Aspect 4] 2. The transaction card of claim 1, wherein the metal layer has at least one discontinuity extending from the periphery of the card to the at least one of the at least two openings in the metal layer. [Aspect 5] 5. The transaction card of embodiment 4, further comprising at least one discontinuity coupled to and extending between the at least two openings. [Aspect 6] A transaction card as described in aspect 4, wherein the metal layer has a first discontinuity extending from the periphery of the card to the opening that houses the transponder module and a second discontinuity extending from the periphery of the card to the opening that houses the LED module. [Aspect 7] 2. The transaction card of embodiment 1, further comprising at least one non-metallic layer disposed on each of the opposing surfaces of the metallic layer. [Aspect 8] 2. The transaction card of claim 1, further comprising a printed pattern on the illumination area of the LED module. [Aspect 9] 2. The transaction card of claim 1, wherein the lighting circuit is configured to have variable lighting characteristics that depend on the characteristics of the harvested energy. [Aspect 10] 10. The transaction card of claim 9, wherein the lighting circuit includes at least one LED having variable intensity, the LED being configured to illuminate at a first relatively low intensity in response to input energy within a first relatively low range, and to illuminate at a second relatively high intensity in response to input energy within a second relatively high range. [Aspect 11] the lighting circuit has at least two LEDs and is configured to illuminate one of the at least two LEDs in response to input energy within a first relatively low range and to illuminate the other of the at least two LEDs in response to input energy within a second relatively high range; 10. The transaction card of embodiment 9. [Aspect 12] A transaction card as described in claim 11, wherein the first range and the second range overlap, such that the lighting circuit is configured to light both of the at least two LEDs when the harvested energy is within the overlapping range. [Aspect 13] 10. The transaction card of embodiment 9, wherein the at least two LEDs are each configured to emit the same wavelength of light. [Aspect 14] 12. The transaction card of claim 11, wherein at least one of the at least two LEDs is configured to emit a different wavelength of light than the other of the at least two LEDs. [Aspect 15] 15. The transaction card of claim 14, wherein one of the at least two LEDs is configured to generate light wavelengths within the green visible spectrum and the other of the at least two LEDs is configured to generate light wavelengths within the red visible spectrum. [Aspect 16] 16. The transaction card of claim 15, wherein the lighting circuit is configured to illuminate a red LED in response to input energy within a first relatively low range, illuminate a green LED in response to input energy within a second relatively high range, and illuminate both the red LED and the green LED in response to input energy within a third intermediate range between the first relatively low range and the second relatively high range. [Aspect 17] 17. The transaction card of embodiment 16, wherein one or both of the red LED and the green LED are configured to illuminate with variable intensities. [Aspect 18] 2. The transaction card of claim 1, wherein the LED module is positioned within the metal layer in a location that improves RF performance of the transponder module compared to a card without the LED module. [Aspect 19] 2. The transaction card of claim 1, wherein the LED module further includes a light guide for distributing light emitted by the one or more LEDs throughout the illumination area. [Aspect 20] 2. The transaction card of embodiment 1, wherein the LED module is an OLED module. [Aspect 21] 2. The transaction card of claim 1, wherein the lighting circuit includes a voltage step-up or voltage step-down component. [Aspect 22] 22. The transaction card of embodiment 21, wherein the lighting circuit includes a charge pump. [Aspect 23] For transaction cards: a metal layer having an appearance, a thickness, a metal layer front side, a metal layer back side, and one or more windows or pockets extending through at least the front side; a transponder module and an insert disposed respectively within the one or more windows or pockets, the insert having an insert front side visible through the window, the insert front side having an appearance different from the metal layer; One or more non-functional features visible from the front surface of the card in contrast to the appearance of the front-facing surface of the insert located below the non-functional features, the insert comprising: (a) is non-transparent and non-translucent; or (b) transparent or translucent and configured to transmit backlight through the back surface of the card to the non-functional features; non-functional features; wherein the insert is positioned within the metal layer in a location that improves RF performance of the transponder module compared to a card in which the insert is absent. [Aspect 24] 24. The transaction card of embodiment 23, wherein the non-functional features include printed features. [Aspect 25] 24. The transaction card of embodiment 23, wherein the insert is non-transparent and non-translucent but has an illuminatable front-facing surface. [Aspect 26] 24. The transaction card of embodiment 23, wherein the insert includes an illuminable LED display. [Aspect 27] 27. The transaction card of embodiment 26, wherein the illuminatable LED display is powered by energy harvested from RF waves. [Aspect 28] 27. The transaction card of claim 26, wherein the metal layer has at least two openings, the transponder module is positioned in one of the at least two openings, and the insert is positioned in the other of the at least two openings. [Aspect 29] 29. The transaction card of embodiment 28, wherein the transponder module includes transaction circuitry configured to inductively couple the transponder module to a card reader using RFID technology. [Aspect 30] 27. The transaction card of embodiment 26, wherein the illuminable LED display is configured to illuminate as an indicator of the operability of the card. [Aspect 31] 27. The transaction card of embodiment 26, wherein the illuminable LED display is configured to illuminate regardless of the status of a payment transaction conducted by the transaction circuit. [Aspect 32] 24. The transaction card of claim 23, wherein the insert is translucent or transparent, the window extends from the front surface of the metal layer to the back surface of the metal layer, and non-collimated light passes through the insert to provide contrast with the one or more non-functional features visible from the front surface of the card. [Aspect 33] Aspect 24. The transaction card of aspect 23, wherein the non-functional features include at least one of printed features, engraved features, etched features, or cut features. [Aspect 34] A transaction card as described in aspect 23, wherein the window or pocket includes a plurality of openings in the front surface of the metal layer defining the one or more non-functional features disposed within a first area, at least one opening in the back surface of the body aligned with the first area, and the insert, wherein the front-facing surface of the insert is positioned with the front-facing surface of the insert recessed relative to the front surface of the metal layer such that the front-facing surface of the insert is visible through the plurality of openings in the front surface of the metal layer. [Aspect 35] 24. The transaction card of embodiment 23, further comprising a backing layer laminated to the back side of the body. [Aspect 36] A transaction card as described in aspect 23, wherein the insert or a portion of the opening that stores the insert is partially obscured by printed or decorative content. [Aspect 37] A transaction card as described in aspect 23, further comprising a first discontinuity extending from the periphery of the card to the opening that stores the transponder module, and a second discontinuity extending from the periphery of the card to the opening that stores the LED module. [Aspect 38] A transaction card as described in embodiment 26, wherein the illuminable LED display includes one or more LEDs configured to emit light and a light guide for distributing the light emitted by the one or more LEDs across an illuminated area of the front-facing surface of the insert. [Aspect 39] 28. The transaction card of embodiment 27, wherein the illuminable LED display has variable lighting characteristics dependent on the amount of energy drawn thereto.

Claims

1. A transaction card having opposing finished surfaces and a periphery: a metal layer having opposing surfaces and at least two openings, each opening extending through one or both of the opposing surfaces; at least one discontinuity connected to and extending between the at least two openings; a transponder module disposed within one of the at least two openings in the metal layer, the transponder module including components in a transaction circuit configured to wirelessly communicate with a card reader configured to emit radio frequency (RF) waves having energy, the transaction circuit configured to receive an input RF signal from the card reader, respond with an output RF signal, and power the transaction circuit by harvesting energy from the RF waves; a light emitting diode (LED) module disposed within another of the at least two openings in the metal layer, the LED module having a planar illumination area visible from a finished surface of the transaction card, the LED module including one or more LEDs configured to emit light and including components in an illumination circuit configured to harvest energy from the RF waves to power the one or more LEDs; Including, The transaction card, wherein the LED module includes an organic light emitting diode (OLED) module.

2. 10. The transaction card of claim 1, wherein the illumination circuitry is configured to illuminate regardless of the status of a payment transaction being conducted by the transaction circuitry.

3. 10. The transaction card of claim 1, wherein the illumination circuit and the transaction circuit constitute components within an integrated circuit in which the illumination circuit is configured to illuminate in a manner indicating the status of a payment transaction being conducted by the transaction circuit.

4. 2. The transaction card of claim 1, wherein the metal layer has a first discontinuity extending from the periphery of the transaction card to the opening that houses the transponder module and a second discontinuity extending from the periphery of the transaction card to the opening that houses the LED module.

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

6. The transaction card of claim 1 , further comprising a printed pattern on the planar illumination area of the LED module.

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

8. 8. The transaction card of claim 7, wherein the illumination circuit includes at least one LED having variable intensity, the LED configured to illuminate at a first relatively low intensity in response to input energy within a first relatively low range, and to illuminate at a second relatively high intensity in response to input energy within a second relatively high range.

9. the lighting circuit has at least two LEDs and is configured to illuminate one of the at least two LEDs in response to incoming energy within a first relatively low field strength range and to illuminate the other of the at least two LEDs in response to incoming energy within a second relatively high field strength range; The transaction card of claim 7.

10. 10. The transaction card of claim 9, wherein the first relatively low field strength range and the second relatively low field strength range overlap, such that the illumination circuit is configured to illuminate both of the at least two LEDs when the harvested energy is within the overlapping range.

11. 10. The transaction card of claim 9, wherein the at least two LEDs are each configured to emit the same wavelength of light.

12. 10. The transaction card of claim 9, wherein at least one of the at least two LEDs is configured to emit a different wavelength of light than the other of the at least two LEDs.

13. 13. The transaction card of claim 12, wherein one of the at least two LEDs is configured to produce light wavelengths in the green visible spectrum and the other of the at least two LEDs is configured to produce light wavelengths in the red visible spectrum.

14. 14. The transaction card of claim 13, wherein the illumination circuit is configured to illuminate a red LED in response to input energy within a first relatively low range, illuminate a green LED in response to input energy within a second relatively high range, and illuminate both the red LED and the green LED in response to input energy within a third intermediate range between the first relatively low range and the second relatively high range.

15. 15. The transaction card of claim 14, wherein one or both of the red LED and the green LED are configured to illuminate with variable intensities.

16. 10. The transaction card of claim 1, wherein the LED module is positioned within the metal layer in a location that improves RF performance of the transponder module compared to a card without the LED module.

17. The transaction card of claim 1 , wherein the LED module further comprises a light guide for distributing light emitted by the one or more LEDs throughout the planar illumination area.

18. The transaction card of claim 1 , wherein the illumination circuit includes voltage step-up or voltage step-down components.

19. 20. The transaction card of claim 18, wherein the illumination circuit includes a charge pump.

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