Metal-Core Payment Card Structure for Durability and Tactile Feel
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Solution Overview
Problem
Current information carrying cards, such as credit and identification cards, face issues with durability and tactile response due to the use of plastic or polymer materials, which fail to withstand flexing and provide a desirable appearance and feel, affecting their functionality and user experience.
Innovation Solution
The development of information carrying cards with a metallic core layer, combined with printable and transparent films, and an electronic layer, which includes advanced security features and a manufacturing process involving prelam formation and lamination, enhances durability and aesthetic appeal while integrating electronic components securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic or polymer material cores are used in information carrying cards, then the cards can be manufactured easily and cost-effectively, but the cards fail to provide desired tactile response, strength, and durability
Solution Approach 1:
The patent applies composite materials by combining a metallic core layer with polymer material layers to create a hybrid card structure. The metallic core provides strength, durability, and tactile response, while the polymer layers provide flexibility and manufacturability. This composite approach resolves the contradiction by integrating the advantages of both material types.
Solution Approach 2:
The card is segmented into multiple functional layers: a metallic core layer for structural integrity and tactile properties, and separate polymer layers for flexibility and manufacturing ease. This segmentation allows each layer to contribute its specific advantages without compromising the other.
2Reliability
If plastic or polymer material cores are used in information carrying cards, then the manufacturing process is simple, but the cards fail to withstand flexing and offer good durability
Solution Approach 1:
The metallic core layer embedded within polymer layers creates a composite structure that enhances reliability. The metal core provides resistance to flexing and structural stability, while the surrounding polymer layers maintain flexibility and protect the metal components. This composite design improves durability without excessive complexity.
Solution Approach 2:
Different regions of the card have different material properties optimized for their specific functions. The metallic core provides localized strength and rigidity where needed, while the polymer layers provide flexibility and protection in other regions. This local optimization of material properties enhances overall reliability.
3Ease of operation
If plastic or polymer material cores are used in information carrying cards, then the production cost is lower, but the cards fail to provide appealing appearance and tactile response
Solution Approach 1:
The combination of metallic and polymer materials creates a card with superior tactile response and appearance. The metallic core layer provides a premium feel, weight, and aesthetic appeal that enhances user experience, while the polymer layers maintain cost-effectiveness and manufacturability.
Solution Approach 2:
The metallic material is applied locally in the core layer where it provides the most value for tactile response and appearance, while polymer materials are used in regions where flexibility and cost-effectiveness are prioritized. This localized material selection optimizes user experience while controlling costs.
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 metallic core layer increases the cards' durability and weight, providing a desirable tactile response and appearance, while the electronic and security features enhance functionality and security, resulting in a more robust and user-friendly information carrying card.
Implementation Method 1
The metallic core layer increases the cards' durability and weight
Implementation Method 2
a manufacturing process involving prelam formation and lamination
Data Source
AI summary
A card manufacturing system includes a locating device and a separation device. A laminate sheet comprising a plurality of cards is received by the locating device and is imaged using first and second imaging modalities. The first imaging modality identifies a location of each of the plurality of information carrying cards within the laminate sheet and the second imaging modality images at least one graphic formed on a surface of the laminate sheet. A position of the at least one graphic with respect to at least one information carrying card is determined and the plurality of cards are removed from the laminate sheet using information corresponding to the location of each of the plurality of information carrying cards when the position of the at least one graphic with respect to the information carrying cards is within a predetermined range.