Ceramic Transaction Card With Metallic Backer

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Solution Overview

Problem

Conventional transaction cards made from thermoplastic materials are susceptible to damage from environmental exposure, such as moisture and sunlight, leading to warping, cracking, and loss of functionality.

Innovation Solution

A ceramic-containing transaction card with a metallic card backer, featuring a ceramic card body and a laser-processed surface for enhanced durability and security, which includes a microchip and RF signal distribution improvements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If thermoplastic materials are used for transaction cards, then ease of manufacture is improved, but durability and resistance to environmental damage deteriorate

Engineering Contradiction:

Improveease of manufactureVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies composite materials by combining ceramic material for the card body with metallic material for the card backer. The ceramic provides superior durability, scratch resistance, and environmental stability, while the metallic backer offers structural support and signal distribution. This composite structure resolves the contradiction by achieving both manufacturability through established bonding processes and enhanced reliability through material properties that resist warping, cracking, and environmental damage.

Inventive Principle:

Principle #40Composite materials

2Strength

If ceramic material is used for card body, then strength and durability are improved, but manufacturing complexity increases

Engineering Contradiction:

ImprovestrengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent segments the transaction card into two distinct components: a ceramic card body and a metallic card backer. This segmentation allows each component to be manufactured using optimized processes for its specific material properties, then bonded together. The ceramic body can be formed, fired, and finished separately, while the metallic backer can be prepared with bonding surfaces independently, reducing overall manufacturing complexity despite the advanced materials used.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses an intermediary bonding process to join the ceramic card body to the metallic card backer. This intermediary step facilitates the integration of dissimilar materials by providing compatible bonding surfaces and processes, thereby managing the manufacturing complexity of combining ceramic and metal components while achieving superior strength and durability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If ceramic card body is used, then resistance to environmental damage is improved, but susceptibility to shattering remains

Engineering Contradiction:

Improveresistance to environmental damageVSAvoidsusceptibility to shattering

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent implements beforehand cushioning by incorporating a metallic card backer that serves as a protective substrate behind the ceramic card body. This metallic backer acts as a cushioning element that prevents catastrophic failure by providing structural support and containing fragments if the ceramic body shatters, thereby maintaining card functionality and reducing susceptibility to complete failure from impact or stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If laser processing is applied to ceramic surface, then security and durability are improved, but manufacturing time increases

Engineering Contradiction:

ImprovesecurityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical marking or embossing methods with laser processing on the ceramic surface. Laser technology provides precise, contactless marking and texturing that enhances security features and durability without mechanical contact. While laser processing adds a step, it eliminates the need for multiple mechanical operations, tool changes, and post-processing, thereby optimizing overall manufacturing efficiency and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The ceramic-containing transaction card offers improved strength, durability, and resistance to environmental damage, maintaining functionality even if the ceramic body shatters, while providing secure and efficient transaction capabilities.

Implementation Method 1

a laser marked feature disposed on the card body and a laser etched feature disposed on the card body

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS10331994B2Method for creating ceramic-containing transaction cards

Publication Date: 2019.06.25 AMERICAN EXPRESS TRAVEL RELATED SERVICES CO INC

AI summary

A transaction card includes a card body that may comprise a card body comprising a ceramic material, the card body including a primary surface and a first mating surface. A card backer comprises a metallic material and includes a secondary surface and a second mating surface. A portion of the first mating surface and a portion of the second mating surface are coupled together.