Multilayer Transaction Card with Metal-Polymer Composite

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Solution Overview

Problem

Existing transaction cards made of plastic are prone to wear and breakage due to their flimsiness, lacking strength and durability.

Innovation Solution

A transaction card constructed with a metal front layer, such as stainless steel plated with gold, and a polymer or polycarbonate back layer, providing increased strength, rigidity, and a unique feel, along with embedded security features like RFID chips and holograms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plastic material is used for transaction cards, then manufacturing cost is low and ease of manufacture is high, but strength and durability are insufficient

Engineering Contradiction:

Improvecard strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by combining metal layer (stainless steel or aluminum) with polymer layer (PVC, PET, or polycarbonate) to create a transaction card that achieves superior strength and durability while maintaining manufacturability. The metal layer provides structural integrity and rigidity, while the polymer layer provides flexibility and ease of manufacturing, resolving the contradiction between strength and ease of manufacture.

Inventive Principle:

Principle #40Composite materials

2Duration of action of stationary object

If metal layer is added to increase strength, then durability and rigidity are improved, but weight increases

Engineering Contradiction:

Improvecard lifespanVSAvoidcard weight

Core Design Contradiction:

Duration of action of stationary objectVSWeight of moving object

Solution Approach 1:

The patent applies local quality by using a thin metal layer (20-100 micrometers) only where structural strength is needed, rather than making the entire card from heavy metal. The metal layer provides the necessary durability and rigidity for card lifespan, while the thin configuration and combination with lightweight polymer minimizes overall weight increase.

Inventive Principle:

Principle #3Local quality

3Strength

If thicker card construction is used to increase strength, then durability is improved, but flexibility and comfort feel deteriorate

Engineering Contradiction:

Improvecard strengthVSAvoidcard flexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent applies composite materials with a metal layer (20-100 micrometers) combined with a polymer layer to achieve optimal balance. The metal provides strength and durability, while the polymer provides flexibility and comfort feel, allowing the card to be strong yet flexible without requiring excessive thickness.

Inventive Principle:

Principle #40Composite materials

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 multilayer construction results in a card that is stronger, more durable, lighter, and has a longer lifespan, offering enhanced security and a high-tech appearance.

Implementation Method 1

the metal layer is stainless steel plated with gold

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS9466019B2Transaction cards and associated methods

Publication Date: 2016.10.11 BARCLAYS LIFESTYLES LLC

AI summary

A transaction card having a first layer and a second layer, wherein the first layer is metal and the second layer is a polymer, polycarbonate, or carbon. The metal layer may be stainless steel plated with gold.