Lightweight Transaction Card With Corrugated Core

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Transaction cards, particularly metal ones, are heavy, leading to increased shipping costs and discomfort for users, and existing solutions have not effectively addressed this issue while maintaining structural integrity and aesthetics.

Innovation Solution

Incorporating a corrugated core with alternating peaks and valleys between the outer layers of the card, which reduces material usage and weight while increasing strength and rigidity, and securing an identification chip directly to this core for enhanced adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal substrate is used for the transaction card, then the card has high strength and durability, but the card becomes heavier leading to increased shipping costs and user discomfort

Engineering Contradiction:

Improvecard strengthVSAvoidcard weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The card is segmented into multiple layers including outer layers and a corrugated core, where the corrugated structure divides the internal space into peaks and valleys, reducing material usage while maintaining structural strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The card uses a composite structure combining outer layers with a corrugated core made of lightweight material, creating a multi-material construction that optimizes both strength and weight properties

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If a corrugated core is used to reduce weight, then the card becomes lighter and more cost-effective, but the structural integrity may be compromised

Engineering Contradiction:

Improvecard weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The corrugated core features curved peaks and valleys rather than flat surfaces, and the identification chip is contoured to match this curved geometry, allowing the chip to nestle into the corrugated structure and enhancing structural integrity through shape complementarity

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The outer layers are designed as thin film structures that conform to the corrugated core geometry, providing protective coverage while maintaining the lightweight characteristics of the overall structure

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the identification chip is positioned directly on the corrugated core, then adhesion is enhanced and fraud is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvechip adhesionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The identification chip is contoured with curved surfaces that match the peaks and valleys of the corrugated core, creating a complementary fit that enhances adhesion through shape matching while simplifying the attachment process

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The identification chip is nested into the corrugated core structure, where the chip contours fit within the peaks and valleys of the core, creating an integrated assembly that reduces manufacturing steps

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12182647B2Transaction card with lightweight core

Publication Date: 2024.12.31 CAPITAL ONE SERVICES LLC

AI summary

Provided are transaction cards with a reduced weight core. In some approaches, a transaction card may include a body having a first outer layer opposite a second outer layer, and a corrugated core between the first outer layer and the second outer layer, wherein the corrugated core comprises a plurality of alternating peaks and valleys coupled to the first outer layer and the second outer layer. The transaction card may further include an identification chip positioned through the first outer layer, wherein the identification chip is directly coupled to the corrugated core.