Metal-Core Card Laminate for Durability and Tactile Response

Solution Overview

Problem

Current information carrying cards, such as credit and identification cards, face issues with durability and tactile response due to their plastic or polymer material cores, which fail to withstand flexing and provide an appealing appearance and feel, affecting their usability and adoption.

Innovation Solution

The use of a metallic or high-density core layer in information carrying cards, combined with printable and transparent films, and an electronic layer, along with advanced manufacturing processes like lamination and singulation, to enhance durability and aesthetic appeal while incorporating security features like EMV chips.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic or polymer material cores are used in information carrying cards, then the manufacturing cost is low and ease of manufacture is improved, but the durability and tactile response deteriorate

Engineering Contradiction:

Improveease of manufactureVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs a composite structure consisting of a plastic or polymer core layer combined with a metallic coating layer. The core layer provides manufacturing advantages while the metallic coating enhances durability, tactile response, and appearance. This composite approach allows the card to benefit from both materials' properties simultaneously.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic or polymer material cores are used in information carrying cards, then the manufacturing simplicity is improved, but the tactile response and appearance deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidtactile response

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent employs a composite structure consisting of a plastic or polymer core layer combined with a metallic coating layer. The core layer provides manufacturing advantages while the metallic coating enhances durability, tactile response, and appearance. This composite approach allows the card to benefit from both materials' properties simultaneously.

Inventive Principle:

Principle #40Composite materials

3Quantity of substance

If plastic or polymer material cores are used in information carrying cards, then the production cost is reduced, but the strength and durability deteriorate

Engineering Contradiction:

Improveproduction costVSAvoidstrength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent employs a composite structure consisting of a plastic or polymer core layer combined with a metallic coating layer. The core layer provides manufacturing advantages while the metallic coating enhances durability, tactile response, and appearance. This composite approach allows the card to benefit from both materials' properties simultaneously.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11650570B2Card having metallic core layer and systems and methods for card manufacturing

Publication Date: 2023.05.16 IDEMIA FRANCE SAS

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.