Metallic Core Payment Card Structure for Flex Durability

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Solution Overview

Problem

Current information carrying cards made of plastic or polymer materials lack durability and tactile appeal, failing to withstand flexing and providing a desirable user experience.

Innovation Solution

The use of metallic or high-density core layers in conjunction with printable and transparent films, along with advanced security features like EMV chips and self-leveling electronic components, to create a durable and aesthetically appealing card with enhanced security and functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic or polymer material cores are used, then the card can be manufactured easily, but the card lacks durability and tactile appeal

Engineering Contradiction:

Improveease of manufactureVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses a composite core structure consisting of a metallic layer (providing strength, durability, and tactile appeal) combined with polymer materials (enabling ease of manufacture and flexibility). This composite approach allows the card to simultaneously achieve the durability of metal and the manufacturability of plastic, resolving the technical contradiction between ease of manufacture and strength.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic or polymer material cores are used, then the card can be manufactured easily, but the card fails to withstand flexing

Engineering Contradiction:

Improveease of manufactureVSAvoidwithstand flexing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The metallic layer in the composite core provides structural rigidity and resistance to flexing damage, while the polymer layers maintain flexibility and manufacturability. This composite structure enables the card to withstand repeated flexing without damage, resolving the contradiction between ease of manufacture and reliability under flexing conditions.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If plastic or polymer material cores are used, then the card can be manufactured easily, but the card lacks tactile appeal

Engineering Contradiction:

Improveease of manufactureVSAvoidtactile appeal

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The metallic layer in the composite core provides a premium tactile feel and visual appeal that enhances user perception and acceptance, while the polymer components maintain ease of manufacture. This combination resolves the contradiction between ease of manufacture and tactile appeal by integrating materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11226610B2Card having metallic core layer and systems and methods for card manufacturing

Publication Date: 2022.01.18 IDEMIA FRANCE SAS

AI summary

A card manufacturing system includes a locating device and a separation device. The locating device is configured to identify a position of one or more information carrying cards formed integrally with a laminate sheet and generate information corresponding to the position of the one or more information carrying cards. The separation device includes at least one singulation mechanism configured to separate each of the one or more information carrying cards from the laminate sheet. The singulation mechanism separates the one or more information cards based on the information corresponding to the position of the one or more information carrying cards.