Multilayer Composite Backed Card Using Adhesive Bonding
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Solution Overview
Problem
Conventional transaction card manufacturing techniques struggle to incorporate non-traditional materials as non-support layers while meeting ISO/IEC 7810 standards for flexibility and durability, as these materials are often too brittle and costly when used as structural supports.
Innovation Solution
A multilayer transaction card construction using a non-plastic material as a non-support layer, combined with a composite fiber material as a support layer, bonded together with an adhesive to achieve the required thickness and structural integrity, allowing for the incorporation of non-traditional materials like metals, wood, or ceramics without compromising rigidity or durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-traditional materials (metals, wood, ceramics) are used as structural support layers in transaction cards, then aesthetic differentiation and unique customer experience are improved, but the card becomes too brittle to meet ISO/IEC 7810 standards for flexibility and durability
Solution Approach 1:
The card is divided into two distinct layers: a non-traditional material layer (metal, wood, or ceramic) providing aesthetic differentiation, and a traditional plastic support layer providing structural integrity. This segmentation allows each material to fulfill its optimal function without compromising the other.
Solution Approach 2:
The invention creates a composite card structure by bonding non-traditional materials to a plastic support layer. This composite approach combines the aesthetic properties of non-traditional materials with the flexibility and durability of traditional plastics, meeting both aesthetic and functional requirements.
2Ease of manufacture
If non-traditional materials are used as structural support layers, then brand differentiation and customer cachet are improved, but production costs become prohibitive
Solution Approach 1:
Instead of making the entire card from expensive non-traditional materials, the invention applies these materials only to a thin aesthetic layer (0.05-0.20 mm), while the bulk of the card structure remains made of cost-effective traditional plastics. This local application of premium materials achieves brand differentiation while controlling production costs.
3Ease of manufacture
If non-traditional materials are used as non-support layers with traditional manufacturing techniques, then aesthetic features are achieved, but the materials are too brittle to meet transaction card standards
Solution Approach 1:
The traditional plastic support layer acts as an intermediary that provides the necessary structural strength and flexibility to support the brittle non-traditional material layer. This mediator allows the aesthetic layer to be incorporated without compromising the card's mechanical properties.
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
This approach enables the use of non-traditional materials for aesthetic and emotional differentiation while maintaining the necessary structural integrity and compliance with ISO/IEC 7810 standards, making such cards suitable for various card readers and reducing production costs.
Implementation Method 1
an adhesive affixing the first card component and second card component together
Data Source
AI summary
A transaction card is disclosed. The transaction card may include a first card component of non-plastic card material having a thickness of no more than about 0.3 mm, a second card component of composite fiber material having a thickness of no more than about 0.3 mm, and an adhesive for affixing the first layer and second layer together. The non-plastic card material may be selected from a group including wood, bamboo, steel, copper, aluminum, silver, gold, platinum, granite, marble, and slate and the composite fiber material may include at least one of a glass fiber composite, a carbon fiber composite, or a natural fiber composite.