Hybrid card capable of implementing various weight and method for manufacturing core sheet for hybrid card

Abstract

The present invention relates to a hybrid card capable of realizing various weights and a method for manufacturing a core sheet for a hybrid card, wherein a metal powder through which electromagnetic waves can pass is mixed with an insulating plastic material in which an upper core sheet and a lower core sheet are formed. The hybrid card according to the present invention is characterized in that the upper core sheet (10) and the lower core sheet (20) are each formed of plastic containing metal powder, an antenna coil (15) is embedded in the upper core sheet (10), the upper core sheet (10) and the lower core sheet (20) are laminated, an upper printed sheet (30) is laminated to the upper surface of the upper core sheet (10), and a lower printed sheet (40) is laminated to the lower surface of the lower core sheet (20).

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a hybrid card capable of realizing various weights and a core sheet for a hybrid card, and more specifically, to a method for manufacturing a hybrid card capable of realizing various weights and a core sheet for a hybrid card in which a metal powder through which electromagnetic waves can pass is mixed with an insulating plastic material in which an upper core sheet and a lower core sheet are formed. Background Technology

[0003] Generally, credit cards are broadly classified into plastic cards, half-metal cards (metal-plastic cards), and full-metal cards depending on the type of material.

[0004] Plastic cards are manufactured with a weight of 5g or less, half-metal cards with a weight of 13g to 17g, and full-metal cards with a weight of 28g to 30g. However, it was difficult to meet the demand for other weights.

[0006] Korean Patent No. 10-1983028 (registered on May 22, 2019) describes a "method for manufacturing a metal card of a hybrid material."

[0007] The method for manufacturing a metal card of the above-described hybrid material comprises the step of placing a hot-melt adhesive between metal plates composed of a non-ferrous metal aluminum plate and a material selected from stainless steel, copper, and titanium that is heavier than the aluminum plate, and performing a laminating step involving heating and pressurizing to complete a card body in which the aluminum plate, the hot-melt adhesive, and the metal plates are sequentially laminated;

[0008] A step of forming a shallow guide groove by milling the surface of the above aluminum plate, and then inserting an IC chip into the guide groove and attaching it with an adhesive;

[0009] A step of completing a metal card by cutting along the outer shape of a card while processing a metal plate of a hybrid material, in which the above aluminum plate and metal plate are joined, using a CNC machine.

[0010] A step of forming an oxide treatment layer by grinding the bottom surface of the above aluminum plate with aluminum oxide or roughening it using a sandblasting method; and

[0011] The method further includes a step of forming an oxide treatment layer by polishing the upper surface of a metal plate with aluminum oxide or roughening it using a sandblasting method, and

[0012] The outer surface of the card body further includes a step of coating and curing a two-component urethane paint, thereby treating the surface of the metal card to give a smooth feel.

[0013] However, the above-mentioned method for manufacturing metal cards using hybrid materials has the disadvantage that when a card body is made by laminating aluminum and metal plates, the card size is fixed, making it difficult to manufacture cards of various weights, and resulting in low profitability due to increased processing costs and material prices. The problem to be solved

[0015] Accordingly, the objective of the present invention is to provide a hybrid card and a method for manufacturing a core sheet for a hybrid card, wherein the upper core sheet and the lower core sheet are made of an insulating plastic material mixed with metal powder through which electromagnetic waves can pass, thereby eliminating the need for an expensive EMI sheet, enabling RFID communication, allowing for free design of antenna patterns, enabling various selections of the metal powder and metal powder mixture contained in the upper core sheet and the lower core sheet according to customer requirements, enabling various adjustments of the thickness of the upper core sheet and the lower core sheet while corresponding to the card weight required by the customer, and enabling various weights that can realize the feel of a metal card. means of solving the problem

[0017] An example of a hybrid card capable of implementing various weights according to the present invention for achieving the above-mentioned purpose is,

[0018] The upper core sheet and the lower core sheet are each formed of plastic containing metal powder, an antenna coil is embedded in the upper core sheet, the upper core sheet and the lower core sheet are laminated, an upper printed sheet is laminated to the upper surface of the upper core sheet, and a lower printed sheet is laminated to the lower surface of the lower core sheet.

[0019] At this time, the mixing ratio of the plastic powder and the metal powder is characterized by a weight ratio of 0.5:9.5 to 4.0:6.0.

[0020] The above plastic powder uses any one powder selected from polyethylene terephthalate (PET), polypropylene, polyethylene, PEEK (poly-ether-ether-ketone), and polyurethane (PU), and

[0021] The above metal powder is characterized by using a powder mixed with one or more of tungsten, brass, bronze, nickel, cobalt, manganese, magnesium, tungsten carbide, germanium, hafnium oxide, and tantalum oxide.

[0022] The above metal powder is characterized by having a particle size of 200㎛ or less.

[0023] An example of a method for manufacturing a core sheet for a hybrid card according to the present invention is,

[0024] Step of preparing plastic powder;

[0025] Step of preparing metal powder;

[0026] A mixing step for mixing plastic powder and metal powder;

[0027] A pellet manufacturing step of manufacturing pellets by extruding mixed powder;

[0028] It is characterized by including an injection molding step in which pellets are placed into an injection molding machine and injected to form a sheet.

[0029] Another example of a method for manufacturing a core sheet for a hybrid card according to the present invention is,

[0030] Step 1: Collected waste plastic is washed and dried, then crushed through a flake process and manufactured into chips;

[0031] A second step of preparing a casting solution by placing waste plastic chips into a solvent and dissolving them;

[0032] A third step of adding metal powder to the prepared castor solution and mixing while heating to 260-280℃;

[0033] It is characterized by including a fourth step of placing the mixture obtained from the third step into a sheet molding machine and molding it into a sheet. Effects of the invention

[0035] By this, the method for manufacturing a hybrid card capable of realizing various weights and a core sheet for a hybrid card according to the present invention does not require an expensive EMI sheet, enables RFID communication, allows for free design of antenna patterns, enables various selections of metal powders and metal powder mixtures contained in the upper core sheet and lower core sheet according to customer requirements, allows for various adjustments of the thickness of the upper core sheet and the lower core sheet while corresponding to the card weight required by the customer, and has the effect of realizing the feel of a metal card. Brief explanation of the drawing

[0037] FIG. 1 is a cross-sectional view illustrating a hybrid card according to the present invention. FIG. 2 is a flowchart illustrating a method for manufacturing a core sheet for a hybrid card according to a first embodiment of the present invention. FIG. 3 is a flowchart illustrating a method for manufacturing a core sheet for a hybrid card according to a second embodiment of the present invention. Specific details for implementing the invention

[0038] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0039] Referring to FIG. 1, a hybrid card capable of implementing various weights according to the present invention has an upper core sheet (10) and a lower core sheet (20) each formed of plastic containing metal powder, an antenna coil (15) embedded in the upper core sheet (10), the upper core sheet (10) and the lower core sheet (20) laminated, an upper printed sheet (30) laminated to the upper surface of the upper core sheet (10), and a lower printed sheet (40) laminated to the lower surface of the lower core sheet (20).

[0040] At this time, it is preferable to use the upper core sheet (10) and the lower core sheet (20) each formed into a sheet shape by mixing plastic powder and metal powder in a certain ratio.

[0041] In this case, it is preferable to mix the plastic powder and metal powder in a weight ratio of 0.5:9.5 to 4.0:6.0. For example, if the plastic powder is 40-50g, the metal powder can be mixed in a ratio of 400-500g, and the mixture can be mixed and molded by selectively distributing it according to the required weight of the card.

[0042] In particular, the upper core sheet (10) can be processed in the same way as before to embed an antenna coil (15).

[0043] In addition, the above plastic powder may be any one powder selected from polyethylene terephthalate (PET), polypropylene, polyethylene, PEEK (poly-ether-ether-ketone), and polyurethane (PU).

[0044] In this case, it is preferable that the plastic powder has a particle size of 200 μm or less to ensure tissue density.

[0045] The above metal powder may be a powder mixed with one or more of tungsten, brass, bronze, nickel, cobalt, manganese, magnesium, tungsten carbide, germanium, hafnium oxide, and tantalum oxide.

[0046] This is because, depending on the weight of the card required by the customer, one metal powder can be mixed into the plastic, or two or more types of metal powders can be mixed into the plastic.

[0047] For example, tungsten has a density of 19.25 g / cm³. 3 Among the metal powders mentioned above, tungsten powder has the highest density; the more tungsten powder is added, the greater the increase in card weight, and magnesium has a density of 1.75 g / cm³. 3As magnesium powder is added, the increase in card weight becomes smaller, making it easier to meet the card weight required by customers by appropriately adjusting the mixing ratio.

[0048] Therefore, the mixture of the metal powders mentioned above is varied, and weight control becomes easier.

[0049] In addition, it is preferable that the metal powder has a particle size of 200 μm or less, as this is effective in increasing the packing density.

[0050] Additionally, the upper core sheet (10) and the lower core sheet (20) may be implemented with plastic powder and metal powder having the same composition or different compositions.

[0051] For example, if the metal powder of the upper core sheet (10) is tungsten powder, the metal powder of the lower core sheet (20) may also be tungsten powder; and if the metal powder of the upper core sheet (10) is tungsten powder, the metal powder of the lower core sheet (20) may be a mixed powder containing magnesium.

[0052] In this way, if the metal powder components of the upper core sheet (10) and the lower core sheet (20) are different, it is possible to respond more accurately to the weight of the card required by the customer.

[0053] This concept can be applied in the same way to plastic powder.

[0054] Meanwhile, the upper printing sheet (30) and the lower printing sheet (40) are for printing and are means for forming various types of printed materials, such as characters, designs, pictures, and numbers, on their surfaces, and are made of synthetic resin.

[0055] In addition, it is preferable that the outer surfaces of the upper printing sheet (30) and the lower printing sheet (40) are each protected by a transparent overlay film (35, 45).

[0056] The hybrid card capable of realizing various weights according to the present invention configured as described above has the advantage that, since the upper core sheet (10) and the lower core sheet (20) are made of a plastic material that acts as an insulator and a metal powder through which electromagnetic waves can pass is mixed, an expensive EMI sheet is not required, RFID communication is possible, and the antenna pattern design is free.

[0057] In addition, the metal powder and metal powder mixture contained in the upper core sheet (10) and the lower core sheet (20) can be selected in various ways according to the customer's requirements. Since the metal powder and metal powder mixture can be selected in various ways, the thickness of the upper core sheet (10) and the lower core sheet (20) can be adjusted in various ways while responding to the card weight required by the customer, and there is an advantage of being able to realize the feel of a metal card.

[0058] Hereinafter, a method for manufacturing a core sheet for a hybrid card (upper core sheet and lower core sheet) capable of realizing various weights according to the present invention will be described.

[0059] FIG. 2 is a flowchart illustrating a method for manufacturing a core sheet according to a first embodiment of the present invention.

[0060] According to FIG. 2, the method for manufacturing a core sheet according to the present invention performs the step of preparing plastic powder.

[0061] The plastic powder prepared in the step of preparing the plastic powder above is a powder selected from polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), PEEK (poly-ether-ether-ketone), and polyurethane (PU) described above, and preferably has a particle size of 200 μm or less.

[0062] Next, a step for preparing metal powder is performed.

[0063] The metal powder prepared in the step of preparing the metal powder above is a powder mixed with one or more of the previously described tungsten, brass, bronze, nickel, cobalt, manganese, magnesium, tungsten carbide, germanium, hafnium oxide, and tantalum oxide, and it must also have a particle size of 200 μm or less.

[0064] Subsequently, a mixing step is performed to mix the plastic powder and the metal powder.

[0065] The mixing ratio in the above mixing step is as previously explained, and it is preferable to divide both into smaller portions and mix them stepwise at intervals of 20 to 30 minutes.

[0066] Next, a pellet manufacturing step is performed in which the mixed powder is extruded to produce pellets.

[0067] The above pellet manufacturing step is a step of making pellets by cutting while extruding the mixed powder with an extruder while heating it to 200-220℃.

[0068] Here, the reason for making pellets is to perform injection molding.

[0069] Then, an injection molding step is performed in which pellets are fed into an injection molding machine and injected to form a sheet.

[0070] By going through such a process, it becomes possible to manufacture a core sheet for a hybrid card intended by the present invention.

[0071] On the other hand, FIG. 3 shows a method for manufacturing a core sheet according to a second embodiment of the present invention.

[0072] This includes technology for recycling waste plastics.

[0073] According to Fig. 3, a first step is performed in which collected waste plastic is washed and dried, then crushed through a flake process and manufactured into chips.

[0074] In this case, the reason for turning flaked waste plastic into chips is to ensure convenience in storage and maintenance, and to improve quantitative mixing.

[0075] In addition, the aforementioned waste plastic is preferably one selected from the plastics used in the manufacture of plastic powder described above, such as polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), PEEK (poly-ether-ether-ketone), and polyurethane (PU).

[0076] Next, a second step is performed in which waste plastic chips are placed in a solvent and dissolved to prepare a casting solution.

[0077] In this case, it is preferable to use N-dimethylpoamide as the solvent, and it is better to degas by leaving it for a certain period of time, preferably about 24 hours, after performing the second step.

[0078] Afterwards, a third step is performed in which metal powder is added to the prepared castor solution and then mixed while heating to 260-280°C.

[0079] As previously explained, the metal powder used in the third step above may be a powder mixed with one or more of tungsten, brass, bronze, nickel, cobalt, manganese, magnesium, tungsten carbide, germanium, hafnium oxide, and tantalum oxide, and the mixing ratio is also as previously explained.

[0080] Then, a fourth step is performed in which the mixture obtained from the third step is placed into a sheet molding machine and molded into a sheet.

[0081] At this time, the sheet formed through the fourth step can be stored in a wound state, or it can have a form in which a filler is inserted and compressed.

[0082] Furthermore, the above third step may be repeated several times by subdividing the metal powder, and plasticizers, lubricants, antioxidants, heat stabilizers, etc., may be added to improve moldability; however, these are known trace additives and are merely general additives that do not alter the physical properties or characteristics of the molded product.

[0083] In addition, the above fourth step may further include a process of removing foreign substances contained in the mixture and a process of degassing before molding.

[0084] By processing in this way, a core sheet for a hybrid card according to the present invention can be manufactured.

[0086] As described above, the present invention has been explained by specific details such as specific components, limited embodiments, and drawings; however, this is provided merely to aid in a more comprehensive understanding of the invention, and the invention is not limited to the above embodiments. A person skilled in the art can make various modifications and variations from this description.

[0087] Accordingly, the scope of the present invention is not limited to the described embodiments, and all things equivalent to or having equivalent variations to the claims set forth below, as well as the claims set forth below, shall be considered to fall within the scope of the concept of the present invention. Explanation of the symbols

[0089] 10: Upper core sheet 20: Lower core seat 30: Upper printed sheet 40: Bottom printed sheet

Claims

Claim 1 A hybrid card characterized in that an upper core sheet (10) and a lower core sheet (20) are each formed of plastic containing metal powder, an antenna coil (15) is embedded in the upper core sheet (10), the upper core sheet (10) and the lower core sheet (20) are laminated, an upper printed sheet (30) is laminated to the upper surface of the upper core sheet (10), and a lower printed sheet (40) is laminated to the lower surface of the lower core sheet (20), and the upper core sheet (10) and the lower core sheet (20) are each molded into a sheet shape by mixing plastic powder and metal powder in a certain ratio, and the mixing ratio of the plastic powder and metal powder is a weight ratio of 0.5:9.5 to 4.0:6.

0. Claim 2 delete Claim 3 A hybrid card according to claim 1, wherein the plastic powder uses any one powder selected from polyethylene terephthalate (PET), polypropylene, polyethylene, PEEK (poly-ether-ether-ketone), and polyurethane (PU), and the metal powder uses any one or more powders mixed from tungsten, brass, bronze, nickel, cobalt, manganese, magnesium, tungsten carbide, germanium, hafnium oxide, and tantalum oxide. Claim 4 A hybrid card according to claim 3, characterized in that the metal powder has a particle size of 200 μm or less. Claim 5 delete Claim 6 delete

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