Federal Card Services, LLC

Metaland LLC

David Finn

Darren Molloy

Daniel Pierrard

Alex Sanchez

A method of making a smartcard may comprise: providing a metal layer (ML) having a module opening (MO) extending from a front surface of the metal layer to a rear surface thereof; providing a sacrificial layer (SL) on the front surface of the metal layer; filling (from behind) the module opening with thermosetting resin (TR); allowing the thermosetting resin to cure (harden); removing the sacrificial layer; and from the front surface of the metal layer, milling a cavity in the cured (hardened) thermosetting resin for receiving a transponder chip module (TCM). A chip module may be implanted in the milled-out cavity, wherein the thermosetting resin provides mechanical support to the chip module and electrical insulation of the chip module from the metal layer. The smartcard may be 'dual-interface'.

Encapsulating a metal inlay with thermosetting resin and method for making a metal transaction card

Encapsulating the rear side of a top metal layer of a metal transaction card with a thermosetting resin, applying a primer to the front side of the top metal layer and drying in an oven before spraying a thermoset powder coating thereon, laser etching and mechanically engraving graphic elements into the powder coating to reveal the bare metal surface, inkjet printing graphic features to the powder coat. Encapsulating the rear side of a bottom metal layer of the card with a thermosetting resin, applying a primer to the rear side of the bottom metal layer and drying in an oven before digitally printing artwork, applying a protective overlay layer with magnetic stripe to the printed graphics, applying a primer or an adhesive film to the thermosetting to enable lamination of the top metal layer to the bottom metal layer.

Plating and coating of RFID enabled metal transaction cards with mechanically engraved and laser etched features

A transaction card (smartcard) having a front 'continuous' (with no slit) metal layer (ML, FML,) with an opening () for a dual-interface transponder chip module (TCM,) having a module antenna (MA,) on its bond side (not shown). A magnetic shielding layer (MSL,) comprising ferrite material disposed below the front face continuous metal layer. An amplifying element, booster antenna circuit (BAC,) disposed under the magnetic shielding layer. A rear discontinuous metal layer (ML, DML,) with a slit (S,) and a metal ledge () surrounding a module opening (MO,) to function as a coupling frame (CF). A rear plastic layer () formed of non-RF impeding material may capture a magnetic stripe and security elements (signature panel and hologram). A portion of the front face continuous metal layer may protrude downward into the magnetic shielding layer and booster antenna circuit layer. The rear discontinuous metal layer may have an additional slit to regulate the activation distance.

RFID enabled metal transaction cards

Metal layers () of a smartcard (SC,) have module openings () for receiving a transponder chip module (TCM). Thermosetting resin (TR,B,A,B,A,B) coats (encapsulates) the bottom surfaces and fills the module openings of the metal layers. A first metal layer () may have a slit (S;B,) which may also be filled by the thermosetting resin. A second metal layer (ML,) disposed above the first metal layer () may have a slit (S,A) which may also be filled by the thermosetting resin. A booster antenna circuit (BAC,) may be disposed between the first and second metal layers, with magnetic shielding material () disposed between the booster antenna circuit and the second metal layer ().

A transaction card for dual interface communication of a transaction includes a front metal layer without a front discontinuity, a rear metal layer having a rear discontinuity, a chip opening, a transponder chip module, and a booster antenna circuit. The transponder chip module has a module antenna and is received within the chip opening. The booster antenna circuit includes a coupler coil disposed between the front and rear metal layers. In addition, the coupler coil is configured to inductively couple with the rear metal layer for harvesting energy from an electromagnetic field.

RFID enabled metal transaction cards with coupler coil couplings and related methods

Smart card

A transaction card (smartcard) having a front 'continuous' or non-continuous metal layer (ML, CML, DML) with a module opening (MO) for a dual-interface transponder chip module (TCM). Coating polyurethane resin may be used to replace (in lieu of) adhesive film layers and plastic slugs, and to fill module openings, cut-outs and voids in a metal transaction card. The amplifying element (BAC) and magnetic shielding layer may be encapsulated in a polyurethane resin. The resin may further fill and seal the module opening in the front face continuous metal layer and any voids or recesses in subsequent layers. The resin may fill and seal any discontinuity or opening in the rear discontinuous metal layer. The dual interface chip module may be implanted in a milled-out cavity in the polyurethane resin. Removed metal sections may also be encased in polyurethane resin.

Metal containing transaction cards or smartcards (SC) having a slit (S) formed in a metal layer (ML) or metal card body (MCB) which extends from a perimeter edge of the card body to a transponder chip module (TCM), wherein the path of the slit (S) extends to an area underneath a module antenna (MA) of the TCM. The slit (S) does not reach a module opening (MO) for the transponder chip module (TCM). The slit enters the area of the module antenna (MA) overlapping its windings or tracks and follows the form and path of the module antenna (MA). In some embodiments, the module opening (MO) may be omitted. The shape of the module opening (MO) may be other than rectangular, and it may have at least two parallel sides.

RFID-enabled metal transaction cards may include a specially treated thin decorative layer attached to a thick core layer of metal or metal layers (with a discontinuity to function as a coupling frame), or a combination of ceramic and metal separated by a polymeric material, wherein the thin decorative layer is designed to provide selected color(s) and/or selected texture(s) to a surface of the metal core cards. The decorative layer may comprise (a) an anodized metal layer with a discontinuity; or (b) a ceramic layer on a flexible polymeric material. A ceramic-containing transaction card may comprise a monolithic ceramic layer of ultra-thin, flexible zirconia. A PET or PEN layer laminated to the ultra-thin ceramic layer may absorb mechanical stress from flexing or torsion of the ceramic card body.

Metal transaction cards containing ceramic having selected coloring and texture

Apparatus and method for producing contact, contactless and dual-interface metal transaction cards that provides enhanced durability and aesthetics, with increased production efficiency. The cards may include (i) a metal core subassembly comprising a metal layer or layers (metal inlay) having a slit (S) allowing for contactless functionality, and (ii) a UV hard coat on a release-carrier layer disposed on one or both sides of the metal core subassembly, and (iii) everything may be laminated together in a single step, providing a metal face smartcard. The hard coat provides a durable, scratch-resistant surface, and protects underlying layers while allowing the passage of a laser beam to write on or within the underlying layer(s), such as a transparent laser-reactive layer. Techniques for hiding or camouflaging the slit provide a more aesthetically pleasing appearance to the metal transaction card.

Durable dual interface metal transaction cards

(i) Smartcards (SC) manufactured from a web of metal inlays (MI; FIGS.-) with the coupling frame (CF) forming the metal card body (MCB) supported by metal struts (struts). In the production of smartcards having a coupling frame (CF) with a slit (S), the slit may form part of graphic elements (FIGS.-). (ii) Printing and coating techniques may be used to camouflage the slit (FIGS.A-D). (iii) Surface currents may be collected from one location in a card body (CB) and transported to another location (FIGS.AB). A flexible circuit (FC) may be connected to termination points (TP) across the slit (S), or may couple via a patch antenna (PA) with the slit (S). The flexible circuit may couple, via an antenna structure (AS) with the module antenna (MA) of a transponder chip module (TCM).

Dual interface metal cards and methods of manufacturing

A transaction card for dual interface communication of a transaction includes a card body, a chip opening, a discontinuity, and a transponder chip. The card body includes a first metal layer having an outer peripheral edge, a first metal face, and a second metal face. The chip opening includes a first chip hole transversely extending from the first metal face toward the second metal face thereby defining a first metal edge surrounding a predetermined hole shape. The discontinuity extends from the outer peripheral edge to the first metal edge. The transponder chip module has a module antenna and is configured to be received within the chip opening. The module antenna defines an outer antenna edge surrounding a predetermined antenna shape such that the predetermined antenna shape is the same as the predetermined hole shape for improved inductive coupling via the discontinuity during use.

RFID enabled metal transaction card with shaped opening and shaped slit

A transaction card (smartcard) having a front 'continuous' (with no slit) metal layer (ML, CML) with an opening (MO) for a dual-interface transponder chip module (TCM) having a module antenna (MA) on its bond side. A magnetic shielding layer (MSL) comprising ferrite material disposed below the front face continuous metal layer. An amplifying element, booster antenna circuit (BAC) disposed under the magnetic shielding layer. A rear discontinuous metal layer (ML, DML) with a slit (S) and a metal ledge surrounding the module opening to function as a coupling frame (CF). A rear plastic layer formed of non-RF impeding material may support a magnetic stripe and security elements (signature panel and hologram). A portion of the front face continuous metal layer may protrude downward into the magnetic shielding layer and booster antenna circuit layer. The rear discontinuous metal layer may have an additional slit to regulate the activation distance.

An RFID enabled metal transaction card comprising (i) a transponder chip module (TCM) having a RF payment chip (IC) and a module antenna (MA), (ii) a coupling frame (CF) in the form of a metal card body (MCB) having an electrical discontinuity comprising a slit (S, S) and (iii) a discontinuous metal frame (DMF) assembled to the metal card body (MCB) in a peripheral area thereof and having a slit (S, S). The discontinuous metal frame (DMF) is electrically isolated from the metal card body (MCB) and may be coated with an insulating medium. The DMF camouflages the slit in the metal card body and mechanically stabilizes the structure of the card body, especially during insertion in an automatic teller machine (ATM) or point of sale (POS) terminal.

Smartcards (SC) having a metal layer (ML) or metal card body (MCB) and a module opening (MO) for a transponder chip module (TCM). A slit (S) or notch (N) in the metal card body may extend from a peripheral edge of a metal layer or card body, without extending to the module opening. A flexible circuit (FC) with one or two patch antennae (PA) or sense coils (SeC) connected to a coupling loop structure (CLS) with an antenna structure (AS) on the same substrate may be incorporated into the card body (CB). A fingerprint sensing module comprising an electrically-conductive metal bezel housed in the card may be electrically isolated from the metal layer or metal card body by the application of coatings (DLC) or anodizing (oxidizing) the respective metal surfaces. The cards may be contactless only, contact only, or dual-interface (contact and contactless).

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Füssen Weissensee, Germany

David Finn