Transaction instrument containing metal inclusions

The present invention relates to a transaction instrument, more particularly to a transaction instrument comprised of a plastic with at least one metal inclusion.

A vast number of financial transactions today involve a transaction or payment card such as a credit card, debit card, stored-value card or automated teller machine (ATM) card. Such cards are typically comprised of plastic. However, a growing number of consumers desire to have a transaction card that has a status element to it such as a weightier card. As a result, a number of card issuers have attempted to manufacture such cards. Some cards have been made of all metal.

However, there are a number of disadvantages associated with such cards including the elevated costs associated with manufacturing and machining such cards, and paying the manual labor costs associated with the manufacturing processes for such cards as well as difficulties in personalizing or embossing metal. Additionally, destruction and disposal of solid metal cards can be difficult, since they cannot be shredded, cut, or easily broken into pieces. Hence, there is a need to make an alternative card that satisfies these consumer needs and also can be manufactured in a more efficient and cost effective manner.

As noted above, payment cards are used every day for financial transactions throughout the world. The most common examples of payment cards are credit cards and debit cards. However, there are also disadvantages associated with the card shape. The traditional card is typically kept in a wallet, purse, or pocket. There are occasions when these methods of carrying may be inconvenient—for example, they may interfere with athletic activities, or may be prone to theft.

Hence, there is a need to make an alternative object that satisfies these consumer needs and also can be manufactured in a more efficient and cost effective manner.

The present invention relates to a transaction instrument and a method of making the transaction instrument.

In an embodiment of the invention, the transaction instrument comprises a combination of a plastic and a metal inclusion, preferably a plurality of metal inclusions. The metal inclusion is embedded or encased in the plastic, and the metal inclusion is in a form of a bit, piece, strand, strip, mesh, web, or combination thereof.

In an embodiment of the invention, the metal inclusion contains at least one heavy gravity metal component or metal.

In an embodiment of the invention, a method for making a transaction instrument comprises embedding or encasing a metal inclusion in plastic, and the metal inclusion is in a form of a bit, piece, strand, strip, mesh, web, or combination thereof.

In an embodiment of the invention, the transaction instrument is a card.

In an embodiment of the invention, the transaction card has a card body with a layer having an antenna and an area containing one or more metal inclusions surrounded by the antenna.

In an embodiment of the invention, the transaction instrument is in a form of a ring, wrist band, watch, pendant, fob, bracelet, charm, stylus, or other non-card form factor.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

The present invention will become more fully understood from the detailed description and the accompanying drawings, which are not necessarily to scale, wherein:

FIG. 1 illustrates a single layer transaction card in accordance with aspects of the present invention.

FIG. 2 illustrates a multi-layer transaction card in accordance with aspects of the present invention.

FIG. 3 illustrates a split core of a transaction card in accordance with aspects of the present invention.

FIG. 4 illustrates a layer of a card body of a transaction instrument, with the layer having an antenna and an area containing one or more metal inclusions.

FIG. 5 illustrates an extrusion process.

FIG. 6 illustrates a calendaring process.

FIG. 7 illustrates an in-line lamination process.

FIG. 8A illustrates a non-card form factor having a shaped body in a form of a watch.

FIG. 8B illustrates a non-card form factor having a shaped body in a form of a bangle or a ring.

The following detailed description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Further, the term “or” as used in this disclosure and the appended claims is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form. Throughout the specification and claims, the following terms take at least the meanings explicitly associated herein, unless the context dictates otherwise. The meanings identified below do not necessarily limit the terms, but merely provided illustrative examples for the terms. The meaning of “a,” “an,” and “the” may include plural references, and the meaning of “in” may include “in” and “on.” The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may.

The present invention relates to a transaction instrument for use in a financial transaction such as making a purchase or other monetary transaction in commerce. Examples of transaction instruments include, but are not limited to, electronic devices in various forms, cards such as a credit card, debit card, automatic-teller machine (ATM) card, check card, stored-value cards, gift cards, among others. Transaction instruments may communicate with merchant terminals, automatic teller machines (ATM), and bank terminals, among others. Transaction instruments may be associated with various types of financial accounts such as a credit card account, debit card account, automatic-teller machine (ATM) account, direct deposit account, check, closed loop gift card account, open loop gift card account, or a combination thereof.

In accordance with an embodiment of the invention, a transaction instrument may take other various forms including, but not limited to, various electronic devices. Examples of such other electronic devices include, but are not limited to, non-traditionally credit-card shaped devices, including items worn on the body, dangling items, etc., formed, for example, into a fob, ring, watch, wrist band, bracelet, charm, other electronic jewelry, pen, pointer device, or stylus.

In accordance with the present invention, the transaction instrument comprises a plastic and a metal inclusion, preferably a plurality of metal inclusions. The metal inclusion is embedded or encased in the plastic. The metal inclusion is in a form of a bit, piece, strand, strip, mesh, web, or a combination thereof. The web may be in a decorative woven pattern, for example. The metal inclusion may be in a geometric shape or design. For example, the geometric shape or design could be a circle, star, diamond, corporate logo, or other image. The term “metal”, as used herein, includes, but is not limited to, metallic elements, metal-containing compounds, other metal forms, or a combination thereof.

The metal inclusion has a thickness capable of being cut by a shredder or a card cutting die. The metal inclusion is greater in size than 10 microns. Preferably, the metal inclusion has a size on an order of magnitude greater than a micron such as in a range of millimeters. The metal inclusion is in non-particle form.

In an embodiment of the invention, the metal inclusion comprises or is comprised of a conductive metal with relatively low neurotoxicity (less bioactive than lead, mercury, cadmium, for example). Non-limiting examples of conductive metals include, but are not limited to, copper, iron, gold, platinum, and combinations thereof.

In an embodiment of the invention, the metal inclusion comprises or is comprised of a high-gravity or heavy-gravity metal component or material. High-gravity or heavy-gravity materials are generally classified according to specific gravity (SG) levels. Light has a typical specific gravity range of 1.7 to 4. Middle has a typical specific gravity range of 4 to 7. Heavy has a typical specific gravity range of 7 to 15.

High- or heavy-gravity metals or materials that may be particularly suitable for use in the present invention include, but are not limited to, tungsten, silver, zinc, bismuth, titanium, titanium dioxide, calcium carbonate, carbon, barium sulfate, steel, tin, nickel, copper, aluminum, or a combination thereof.

Materials that may be suitable for the plastic include, but are not limited to, polymers and co-polymers. Examples of such polymers and co-polymers that may be used alone or in combination are polypropylene (PP), nylon, polyvinyl chloride (PVC), polyvinyl chloride acetate (PVCA), oriented polyester, polybutylene terephthalate (PBT), thermoplastic polyurethane (TPU), poly(styrene-block-butadiene-block-styrene) (SBS) and hydrogenated versions thereof, polyphenylene sulfide (PPS), polyethylene, polyethylene terephthalate (PET), including biaxially-oriented polyethylene terephthalate, polyethylene terephthalate glycol (PET-G), polycarbonate, acrylonitrile butadiene styrene (ABS), polycarbonate, or a combination thereof.

Other polymers that may be suitable for use in the present invention include, but are not limited to, plant-based polymers and/or protein-based polymers. Examples of plant-based polymers that may be suitable for making the plastics include, but are not limited to, PLA, PLA-PGA, PHA, PHB, or a combination thereof. The plant based polymer can be a starch polymer, which could be combined with a resin for stability. The plant based polymer could also be cellulose including, but not limited to, carboxymethylcellulose combined with various plant based fibers. The polymer could also be a chitin and cellulose composite, with potentially favorable water repellant and strength properties. The polymer could also be chitosan, which has favorable ionic properties which could help it bind with metal particles.

The plastic may further comprise a plasticizer. The plastic may be optically transparent, in whole or in part. The optically transparent plastic may be opaque to some or all light outside of the visible spectrum. The optically transparent plastic may be opaque to ultraviolet light.

In an embodiment of the invention, the metal inclusion has a higher specific gravity than the plastic. The metal inclusion is preferably one of a plurality of metal inclusions in the plastic. The plurality of metal inclusions can be evenly distributed throughout the plastic.

Preferably, the plurality of metal inclusions comprise not less than 40% and not more than about 95% of total blended composite weight of the plastic and the metal inclusions, preferably greater than about 50% to not more than about 95%. Preferably, the plurality of metal inclusions has a volume comprising not less than 5% and not more than 60% of total blended composite volume of the plastic and the metal inclusions. The transaction instrument, when in the form of a card, preferably has a total weight of not less than 10 grams and not more than 30 grams.

The transaction instrument of the present invention can be constructed in a number of configurations when in the form of a card. In one such configuration, the transaction card is a single-layer card comprised of a metal-filled plastic such as a high-gravity compound. FIG. 1 illustrates a single layer transaction card in accordance with aspects of the present invention. The single layer card is formed of the metal-filled plastic and typically has a thickness of about 30 mils. However, it is contemplated and within the scope of the present invention that the thickness may vary. The transaction card may be embossed, laser etched, or machined.

In another configuration, the transaction instrument of the present invention is a multi-layer card. FIG. 2 illustrates a multi-layer transaction card in accordance with aspects of the present invention. As shown in FIG. 2 , the multi-layer card has a central core layer. The central core layer is comprised of a metal and plastic combination. The central core layer has a thickness of about 26 mils. A decorative film layer may be present on the front and back surfaces of the central core layer to sandwich the central core layer. The decorative film layer is about 1 mil in thickness. A clear layer(s) may be present on one or more of the decorative film layers, particularly on the side of the decorative layer that opposes the central core layer. A clear layer is typically about 1 mil in thickness. Paint may be applied to any surface of a decorative film layer.

In another possible configuration, the central core layer is a split core. FIG. 3 illustrates a split core of a transaction card in accordance with aspects of the present invention. As shown in FIG. 3 , the central core layer is split into two layers as opposed to one. For example, each layer is about 12 to 15 mils. Among the advantages of the split core is easier processing. For example, it is easier to print on the front and back of each of the two layers and then laminate the layers back to front rather than printing on both sides of a single layer. In accordance with the present invention, one or more layers of the split core comprises a metal and plastic combination.

The metal and plastic combination layer(s) of the transaction instrument of the present invention can be made by a number of methods of manufacture. In a preferred aspect of the present invention, the transaction instrument is made by lamination of layers with one or more layers comprising a metal and plastic combination. In a preferred aspect of the present invention, the metal and plastic combination is a high-gravity compound. A layer may comprise in whole or in part of a metal and plastic combination and, in the case of a single layer, may be the entire thickness of the instrument.

Referring to FIG. 4 , FIG. 4 illustrates a plastic layer of a card body 110 of a transaction card 100 , with plastic layer 110 comprising an antenna 120 and an area 130 containing one or more metal inclusions 140 . One or more metal inclusions 140 are embedded or encased in plastic layer 110 . Antenna 120 surrounds area 130 containing one or more metal inclusions 140 .

Among the methods of making a plastic layer include, but are not limited to, extrusion, calendaring, casting, blowing or blow molding, injection molding, and additive manufacturing.

One such process is extrusion. An example of a method of making a transaction instrument of the present invention by an extrusion process is shown in FIG. 5 . An extruded film layer can be formed by an extrusion process. Extrusion is a process whereby a plastic material is inserted or forced through a die having a particular shape. This process can be used to create one or more plastic layers.

Another process that may be used to make the transaction instrument of the present invention is calendaring. An example of a method of making a transaction instrument of the present invention by a calendaring process is shown in FIG. 6 . Calendaring is used to make a calendared film. A calendar is a series of hard pressure rollers used to form or smooth a sheet of material such as paper or plastic film. The process begins with the ingredients 3 being mixed, heated and then extruded through a pair of counter-rotating rollers 1 . Additional rollers can be used to further shape or thin the sheet 2 . An embossing station can impart different patterns or levels of gloss to the extruded material. Finally, the film 4 is cooled before being cut into sheets if more rigid, or spooled onto rolls if sufficiently flexible. The material used for the transaction instrument is relatively rigid and would most likely be cut into sheets.

Another method of making the transaction instrument of the present invention is casting. Casting produces cast film. The process begins with the ingredients being mixed and then extruded onto a moving web known as the casting sheet. Ingredients are likely to be liquid or more melted than those at the start of a calendaring process. Unlike calendaring, the material is not itself pulled through rollers, and any dimensional stress is borne by the casting sheet. Since the film has not had any stress applied during the manufacturing process it does not try to resume or shrink back to its original form. Casting may provide an advantage over calendared films which generally shrink a minimum of 2-3% over time. Casting allows the film to be very thin and while it is possible to make a 2 mil sheet either calendaring or casting, there may be greater uniformity and ease of manufacturing with casting.

In another aspect of the method of making the transaction instrument of the present invention, the transaction instrument manufacturing process may employ extrusion. Extruded, calendared, or cast film can employ extrusion, which is the simultaneous production of two or more materials to form a multi-layered film. Co-extrusion can include the manufacturing of different types of layers with different properties. For example, the heavy core of the instrument can be sandwiched between colorful surface layers or clear protection.

Another method of making the transaction instrument of the present invention is injection molding. Injection molding may be stand-alone or around components. Components around which injection molding may occur include, but are not limited to, a chip such as an ME chip, a contactless antenna, a magnetic strip or other components.

Another method of making the transaction instrument of the present invention is additive manufacturing. A thin metal mesh may lend itself to additive manufacturing or continuous liquid interface (CLIP) methods by providing a frame on which to build additional plastic.

The transaction instrument of the present invention has special features. One such feature is a split core as illustrated in FIG. 3 . A core of an instrument that is not split must be turned over to be printed and finished on the other side as part of the instrument or card manufacturing process. This is less efficient. Furthermore, by making two heavy plastic core halves that can be processed separately and then laminated together, the cost in the manufacturing process is reduced. Waste can also be reduced since turning over a single core leads to higher damage and defective product that is discarded.

In still another aspect of the method of making the transaction instrument of the present invention, the manufacturing process may employ in-line lamination. An example of a method of making the transaction instrument of the present invention by in-line manufacturing is shown in FIG. 7 . Similar to co-extrusion, an extruded, calendared, or cast film can be laminated in-line with finished layers such as foils, decorative printed sheets, or protective layers. In-line lamination may also include sheets containing contactless antenna and chip packages.

In another embodiment of the invention, the transaction instrument may be made by three-dimensional (3D) or additive manufacturing.

Thus, there are a number of advantages associated with the plastic-and-metal-combination transaction instruments of the present invention and method of making such instruments. Among the advantages is that metal and plastic combination instruments offer superior weight. They also provide manufacturing cost advantages as compared to metal cards which have high machining and manual labor costs. They also may be personalized through embossing, unlike a more rigid metal card. Furthermore, they are easier and/or more cost effective to destroy than more rigid metal cards.

It is contemplated and within the scope of the present invention that the transaction cards of the present invention can be used for other applications beyond mere financial transactions. For example, the transaction cards of the present invention may be used as include loyalty/affinity cards as well as items like security badges.

There are numerous features associated with the transaction card of the present invention. For example, the transaction card may comprise a chip such as an EMV chip, a recess for an antenna and/or wires, and a magnetic strip, among other features. The transaction card may have varying colors, logos and images and decorative features such as inlaid decoration, various textures, personalization, and braille. Likewise, the transaction card may vary in shape, size or orientation.

As a feature of the invention, the transaction card comprises a recess. The recess may comprise a component or inset device. The inset device may comprise one or more conducting contact pads. The contact pads are preferably located as set forth in ISO 7816. Examples of one or more components or inset devices include, but are not limited to, a chip such as a Europay-Mastercard-Visa (EMV) chip, a contactless antenna, a contactless antenna chip, a magnetic strip, an in-laid decoration, embedded features, and printed features. The recess has a size and a shape to accommodate the component or inset device. Preferably, the recess has a depth in a range of 15 mils to 25 mils at the deepest point.

There are numerous advantages associated with the transaction instrument of the present invention. The presence of the metal inclusions in lieu of the plastic enhances the tactile properties of the transaction instrument as well as enables convenient destruction. In an embodiment of the invention, the metal inclusion is at or near an outer surface of the transaction instrument. Embedded metal inclusions, if near the surface of the card, may create additional tactile appeal by creating texture. For example, strands may create a striated feel, etc. Additionally, embedded metal inclusions may not only improve tactile properties, but may also constitute a security element. In another embodiment of the invention, the metal inclusion comprises a security feature. For example, the metal inclusions may take on shapes that respond to electromagnetic signals or they may be elements that can be seen and/or detected through plastic. For example, the metal inclusions may include printing, etching, holograms, etc. on the metal. Additionally, introduction of metal elements, in sufficient quantity, will allow ATMs and other readers to detect cards even if the plastic component of the card is transparent to the detector (infrared, etc).

In an embodiment of the invention, a method is provided for making a transaction instrument in a form of a three-dimensional object of any shape, also referred to herein as a form factor. A customer or user may wish to have a non-traditionally credit-card shaped device, including, but not limited to, an item to be worn on the body and/or dangling items. In an embodiment of the invention, a method is provided for making a non-credit-card shaped device. The order of the steps may vary. The method generally comprises obtaining a plastic, forming the plastic into a shape, incorporating one or more metal inclusions within the plastic. Alternatively, the method generally comprises obtaining a plastic, incorporating one or more metal inclusions within the plastic, and forming the plastic with one or more metal inclusions therein into a shape for a device. Non-limiting examples of such devices include, but are not limited to, a fob, ring, watch, wrist band, bracelet, charm, other jewelry, pen, pointer device, and stylus.

These objects, especially if worn on the user's person, may have more appeal if they are tactilely pleasing. A plastic object with embedded metal bits, for example, would have the tactile appeal of weight as well as potential cost savings over pure metal in manufacture. If the metal elements were fully enclosed, they would be protected from the elements and would not rust, corrode, etc. The metal elements also create tactile appeal by creating texture on the surface of the object, if they are near the surface.

A form factor has a shaped body and may comprise in a portion of or throughout the shaped body an area comprising a material and one or more metal inclusions. The one or more metal inclusions are present in or distributed throughout the material, preferably in an electrically isolated pattern. An antennae may surround the material having one or more metal inclusions embedded therein. Preferably, the shaped body may be formed by injection molding, 3D printing, additive manufacturing, or any other customary manufacturing method. The form factor may have a recess for a component or inset device. Preferably, the shaped body is in a shape conducive to resonance for Near Field Communication (NFC) and/or is electrically connected to an integrated circuit (IC) unit.

The shaped body can be in a form of a ring, bangle or other jewelry, charm, fob, or card with an optional mesh loop(s) acting as an antenna, conductively connected to an IC, comprising an EMV chip and/or transaction instrument.

In an embodiment of the invention, a transaction instrument comprises a plastic, one or more metal inclusions embedded or encased in the plastic, the metal inclusions comprised of a metal selected from the group consisting of tungsten, silver, zinc, bismuth, molybdenum, iron, steel, tin, copper, titanium, and a combination thereof, and an antenna surrounding the one or more metal inclusions, wherein the one or more metal inclusions are in a non-particle form selected from the group consisting of a bit, a piece, a strand, a strip, a mesh, a web, and a combination thereof, and wherein the transaction instrument is in a form of a torus or a circle and the antenna is embedded concentrically within the torus or circle.

FIG. 8A illustrates a non-card form factor 200 having a shaped body formed of a material in a form of a watch. As shown in FIG. 8A , form factor shaped body 210 is in a form of a watch. Form factor shaped body 210 comprises an antenna 220 surrounding an area 230 with metal inclusions 240 .

FIG. 8B illustrates a non-card form factor 250 having a shaped body formed of a material in a form of a bangle or a ring. As shown in FIG. 8B , form factor shaped body 260 is in a form of a bangle or ring. Form factor shaped body 260 comprises an antenna 270 surrounding an area 280 with metal inclusions 290 .

It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.