Thin Gage Open Loop Card Manufacturing
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Solution Overview
Problem
Traditional 30 mil credit cards are thick, heavy, and costly to produce, with embossing processes compromising material integrity and requiring multiple manufacturing steps, while thin gage cards face perception issues of being less valuable and compatibility problems with older swipe readers and certain personalization features.
Innovation Solution
A thin gage card design and manufacturing method using a single ply plastic material (5-15 mils thick) with direct application of magnetic stripes and high-speed ink jet personalization, eliminating the need for embossing and Mylar carriers, allowing for efficient production on rotary presses and increased personalization rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional 30 mil multilayer PVC cards are used, then card durability and perceived value are improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent applies this principle by transitioning from thick 30 mil multilayer PVC cards to thin gage 5-15 mil single ply cards. The thin card stock with direct magnetic stripe application and ink jet personalization eliminates the need for multiple layers while maintaining functionality, thereby reducing material costs and simplifying manufacturing processes.
Solution Approach 2:
The patent extracts and eliminates unnecessary layers from the traditional card structure. By removing the multilayer construction and using a single ply base with directly applied magnetic stripes and printed personalization, the patent reduces manufacturing steps and material costs while maintaining card durability through the inherent strength of the thin gage plastic material.
2Strength
If embossing process is used on 30 mil cards, then card value perception is improved, but material integrity is compromised and manufacturing steps increase
Solution Approach 1:
The patent replaces the mechanical embossing process with ink jet printing technology. Instead of using embossing machines that mechanically deform the card surface, the patent uses non-contact ink jet printers to apply personalization directly onto the thin gage card surface, eliminating material stress and additional manufacturing steps.
Solution Approach 2:
The patent changes the card thickness parameter from 30 mil to 5-15 mil, which fundamentally alters the manufacturing approach. The thinner card stock is incompatible with traditional embossing but ideal for direct ink jet printing and magnetic stripe application, thereby simplifying the manufacturing process while maintaining material integrity.
3Productivity
If thin gage 5-15 mil single ply cards are used, then production cost and manufacturing efficiency are improved, but customer perception of value may deteriorate
Solution Approach 1:
The patent uses vibrant ink jet printing to apply colorful graphics, patterns, and personalization directly onto the thin gage card surface. This visual enhancement compensates for the reduced thickness by creating an aesthetically appealing card that conveys value through design rather than bulk, thereby improving customer perception.
Solution Approach 2:
The patent incorporates all personalization elements, including magnetic stripe encoding and printed graphics, during the initial card manufacturing process rather than adding them later. This preliminary integration ensures that thin gage cards receive the same level of customization and attention to detail as traditional cards, maintaining perceived value while enabling high-speed production.
4Strength
If multiple layer lamination is used for 30 mil cards, then card strength is improved, but production cost and material usage increase
Solution Approach 1:
The patent utilizes the inherent flexibility and strength of thin gage 5-15 mil single ply plastic material to eliminate the need for multiple protective layers. The thin card stock is engineered to provide sufficient durability without requiring additional lamination layers, thereby reducing material usage and production costs while maintaining card strength.
Solution Approach 2:
The patent employs a composite structure consisting of a single ply plastic base combined with directly applied magnetic stripe material and ink jet printed personalization layers. This composite approach provides the necessary functional properties and strength without requiring multiple structural plastic layers, reducing overall material usage compared to traditional multilayer construction.
Data Source
AI summary
An improved card design and manufacturing method to produce thin gage, open loop system cards, such as credit cards, debit cards, prepaid cards, financial cards, and payroll cards. The thin gage card structure may vary between 5-15 mils in thickness (0.005″ inches to 0.015″ inches) on a one ply plastic material such as PVC or polyester. The majority of manufacturing steps can be performed on a rotary press in a single operation. Card personalization will be accomplished on a high-speed machine using ink jet for all variable information imaged on both the front and back, and accompanied by high speed encoding of magnetic stripe or activation of integrated circuit elements utilized in the electronic payment process.