Transaction card with carbon fiber substructure and method of making same

Abstract

A transaction card has a substructure consisting at least in part of a layer of fibrous material, such as carbon fiber strands or filaments, arranged in a pre-selected pattern, such as a weave pattern, that is at least partially enclosed by a transparent plastic film. A sheet is laminated on each of two opposing faces of the substructure to form a transaction card core. One or both of the sheets laminated on the opposing faces of the substructure is also made of a transparent material, and one or both of the two opposing faces of the transaction card core can be printed. An over-laminate film, such as a transparent polyvinyl chloride plastic film, can be laminated on each of two opposing faces of the transaction card core.

Claims

1. A method of making a transaction card, comprising: arranging a layer of fibrous material in a pre-selected pattern; enclosing the layer of fibrous material at least in part on each side by a transparent plastic film to form a transaction card substructure; laminating a sheet on each of two opposing faces of the transaction card substructure to form a transaction card core, at least one of the sheets comprising a transparent material, and the transparent material comprising transparent polyvinyl chloride plastic; and laminating an over-laminate film on each of two opposing faces of the transaction card core, at least one of the over-laminate films comprising a transparent film.

2. The method of claim 1, wherein arranging the layer of fibrous material in the pre-selected pattern further comprises arranging the layer of fibrous material in a pre-selected weave pattern.

3. The method of claim 1, wherein arranging the layer of fibrous material further comprises arranging the layer of fibrous material comprising carbon fiber strands or filaments in the pre-selected pattern.

4. The method of claim 1, wherein arranging the layer of fibrous material further comprises arranging the layer of fibrous material comprising fiber strands or filaments selected from the group consisting of mineral fiber strands or filaments, glass fiber strands or filaments, metal fiber strands or filaments, and polymer fiber strands and filaments in the pre-selected pattern.

5. The method of claim 1, wherein enclosing the layer of fibrous material to form the transaction card substructure further comprises enclosing the layer of fibrous material at least in part on each side by the transparent plastic film to form a transaction card substructure comprising a substrate material selected from the group consisting of amorphous polyethylene terephthalate plastic, biaxially oriented polyethylene terephthalate plastic, and polyvinyl chloride plastic.

6. The method of claim 1, wherein enclosing the layer of fibrous material to form the transaction card substructure further comprises enclosing the layer of fibrous material at least in part on each side by the transparent plastic film to form a transaction card substructure comprising an adhesive material selected from the group consisting of polyethylene, acrylic, cyanoacrylate, and epoxy.

7. The method of claim 1, wherein laminating the sheet on each of two opposing faces of the transaction card substructure to form the transaction card core further comprises laminating the sheet on each of two opposing faces of the transaction card substructure to form the transaction card core, each of the sheets comprising a transparent material, and the transparent material comprising transparent polyvinyl chloride plastic.

8. The method of claim 1, further comprising, printing at least one of the two opposing faces of the transaction card core.

9. The method of claim 1, wherein the transaction card substructure and the sheets laminated on the two opposing faces of the transaction card substructure each has a predetermined thickness that is substantially identical.

10. The method of claim 1, wherein laminating the over-laminate film further comprises laminating the over-laminate film on each of two opposing faces of the transaction card core, each of the over-laminate films comprising a transparent film.

11. The method of claim 10, wherein laminating the over-laminate film further comprises laminating the over-laminate film on each of two opposing faces of the transaction card core, each of the over-laminate films comprising a transparent polyvinyl chloride plastic film.

12. The method of claim 1, wherein each sheet laminated on each of two opposing faces of the transaction card substructure is approximately 10 mils or less in thickness.

13. The method of claim 1, wherein the transaction card substructure is approximately one-third of the overall thickness of the transaction card.

14. The method of claim 1, wherein the transaction card substructure is approximately 10 mils or less in thickness.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a cross-sectional view of an example of the carbon fiber substructure for a transaction card for embodiments of the invention;

(2) FIG. 2 is a cross-sectional view of an example of the carbon fiber substructure sandwiched between two layers of clear PVC plastic of the inner core of a transaction card for embodiments of the invention;

(3) FIG. 3 is a perspective partially cut-away view of an example of the carbon fiber substructure sandwiched between two layers of clear PVC plastic of the inner core shown in FIG. 2 for a transaction card for embodiments of the invention;

(4) FIG. 4 is a cross-sectional view of an example of the carbon fiber substructure sandwiched between two layers of clear PVC plastic of the inner core over-laminated with clear PVC plastic film for a transaction card for embodiments of the invention;

(5) FIG. 5 is a perspective partially cut-away view of an example of the carbon fiber substructure sandwiched between two layers of clear PVC plastic of the inner core over-laminated with clear PVC plastic film over-laminates for the transaction card shown in FIG. 4 for embodiments of the invention; and

(6) FIG. 6 is a flow chart that illustrates an example of the process of making a transaction card with a carbon fiber substructure for embodiments of the invention.

DETAILED DESCRIPTION

(7) Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations that come within the scope of the invention.

(8) Embodiments of the present invention utilize carbon fiber as a component of a transaction card, such as a credit card, a debit card, a smart card, and/or any other type of transaction card (it being understood that transaction card as used herein includes, without limitation, credit card, debit card, ATM card, gift card, loyalty card, smart card, stored value card, contactless card, access card, payment card, etc.). Such use of carbon fiber as a component of a transaction card not only addresses an issue of aesthetics by providing a unique appearance, but also addresses an issue of practicality by providing a transaction card of extreme durability.

(9) The transaction card for embodiments of the invention incorporates a carbon fiber substructure, such as a woven carbon fiber substructure, into the body of a standard credit card form, such as ISO CR80 [the dimensions of which are 3.3752.125 (85.6 mm54 mm)]. It is to be noted that the reference to the ISO CR80 standard is not intended to be exclusive, and embodiments of the invention include all types and sizes of transaction cards according to any other standard or standards, as well as all types and sizes of non-standard transaction cards.

(10) FIG. 1 shows a cross-sectional view of an example of the carbon fiber substructure 10 for a transaction card for embodiments of the invention. According to embodiments of the invention, carbon fiber strands or filaments are woven into a weave pattern component 12 using commercially available equipment. Thereafter, the weave pattern component 12 is mounted between two layers 14 of thin clear plastic and adhesive 16, such as clear PVC plastic film, as shown in FIG. 1. The thin clear plastic layers 14 hold the carbon fibers together and keep the weave pattern 12 of the substructure 10 intact. The adhesive 16 fills the air voids around the carbon fibers and bonds the fibers to the PVC skin 14.

(11) The substructure 10 is thereafter mounted between clear PVC plastic layers of a transaction card, such as a credit card, and the components are then laminated together to form the inner core of the transaction card. FIG. 2 shows a cross-sectional view of an example of the carbon fiber substructure 10 sandwiched between the two layers 18 of clear PVC plastic, and FIG. 3 shows a perspective partially cut-away view of an example of the carbon fiber substructure 10 sandwiched between the two layers 18 of clear PVC plastic, to form the inner core 20 of the transaction card for embodiments of the present invention.

(12) The outer surface 22 of the inner core 20 of the card can be printed with various text, graphics, logos, phone numbers, and the like, or other printed plastic sheets can be attached by lamination. Materials for the carbon fiber substructure 10 include various combinations of substrates such as both amorphous and biaxially oriented forms of polyethylene terephthalate (PET) plastic or combinations of both, polyvinyl chloride (PVC) plastic, other suitable plastics, adhesives such as polyethylene, acrylic, cyanoacrylate, epoxies, and carbon fibers commonly used for extreme durability strength in airplane structures, automotive components, etc.

(13) Embodiments of the invention involve building the substructure 10 using polyester, polyethylene, acrylic, and/or epoxies with carbon fiber, which is then sandwiched in the middle of the card core 20 between two layers 18 of clear PVC plastic, and possibly two additional layers of thin PVC plastic over-laminate on the outer surfaces of the clear PVC plastic layers 18 of the inner core 20. It is to be understood that while embodiments of the invention employ layers 18 of PVC plastic for the card core 20, any suitable material, such as a composite of PVC and PET, can be used for layers 18 as well. FIG. 4 shows a cross-sectional view of an example of the carbon fiber substructure 10 sandwiched between two layers 18 of clear PVC plastic over-laminated with clear PVC plastic over-laminates 24, and FIG. 5 shows a perspective partially cut-away view of an example of the carbon fiber substructure 10 sandwiched between two layers 18 of clear PVC plastic which are over-laminated with clear PVC plastic over-laminates 24, in a transaction card 26 for embodiments of the present invention.

(14) FIG. 6 is a flow chart that illustrates an example of the process of making a transaction card 26 with a carbon fiber substructure 10 for embodiments of the invention. Referring to FIG. 6, at S1, a layer of fibrous material, such as carbon fiber strands or filaments, is arranged in a pre-selected pattern 12, such as a weave pattern. At S2, the layer 12 of fibrous material is enclosed at least in part by a transparent plastic film 14, such as a thin film of clear PVC, with an adhesive, such as epoxy, to form a substructure 10. Thereafter, at S3, a plastic sheet 18, such as a PVC or PVC/PET composite plastic sheet (at least one of which sheets is clear PVC or PVC/PET composite) is laminated on each of two opposing faces of the substructure 10 to form a transaction card core 20, and at S4, an over-laminate film 24, such as a thin film of clear PVC plastic, is laminated on each of two opposing faces 22 of the transaction card core 20 to form a transaction card 26.

(15) The carbon fiber substructure 10 gives the card 26 for embodiments of the invention strength and torque resistance, an enhanced cosmetic value with a three-dimensional effect, and the two layers 18 of clear PVC or PVC/PET composite plastic of the inner core 20 also serve as the media for printing. The transaction card 26 for embodiments of the invention has potential for extreme durability, as the carbon fibers are very lightweight but extremely strong. Further, the graphics, logos, holograms, and the like are protected by the clear thin PVC plastic over-laminates 24, if used.

(16) As previously noted, a typical conventional credit card consists of two pieces of white PVC plastic inner core or split core materials, 13 mils each, that are joined together to form a white PVC plastic core 27 mils thick, the back and front of which are each then over-laminated with a thin layer of clear or transparent plastic over-laminate to form a transaction card that is 30 mils thick. However, embodiments of the present invention employ a carbon fiber substructure 10 with a thickness of 10 mils more or less sandwiched between two layers 18 of clear or opaque PVC plastic (of which at least one side is clear), each of which is likewise 10 mils or less in thickness, such that the total thickness of the resulting composite 26 is 30 mils (including 2 milslamination film)10%.

(17) The carbon fiber substructure 10 for embodiments of the invention consists of the weave pattern component 12 mounted between two layers 14 of thin film clear PVC with epoxy adhesive that holds the carbon fibers together and keeps the weave pattern 12 intact. The carbon fiber substructure 10 is thus stable with a substantially flat thickness of approximately 10 mils or about one-third of the approximately 30 mils total thickness of the transaction card 26, although embodiments of the invention include carbon fiber substructures 10 having thicknesses that are greater than or less than 10 mils or greater than or less than one-third of the total thickness of the transaction card 26.

(18) The pattern into which the carbon fiber is woven for the carbon fiber substructure 10 for embodiments of the invention can take various forms, such as something similar to a basket weave or any other type of weave pattern. Embodiments of the invention include a predetermined optimum range of carbon fiber strands per weave and a suitable manner in which the strands are overlaid on one another to form a unique appearing weave pattern. The unique weave pattern is due at least in part to the physical and/or chemical properties of the carbon fiber which contributes to its apparent change in appearance depending, for example, on the angle of incident light and the perspective from which it is viewed by an observer.

(19) As previously noted, embodiments of the invention utilize any suitable adhesive material, such as one or more adhesive resins, in fabricating the carbon fiber substructure 10. Further, embodiments of the invention utilize other suitable materials that can be made to resemble carbon fiber including for example, mineral fibers, such as glass and/or metal fibers, and various polymer fibers in fabricating the fiber substructure.

(20) The transaction card 26 employing the carbon fiber substructure 10 for embodiments of the invention is useable in all respects in exactly the same way as a conventional transaction card, for example, in a card reader, card printer, or other card handling mechanism. For example, the transaction card for embodiments of the invention can be tipped, embossed, can have a signature panel applied, can have a hologram applied, and can be printed, etc. in the same way as any conventional transaction card.

(21) Further, the transaction card 26 for embodiments of the invention can be embossed, embedded with a microchip for a smart card or can have one or more magnetic stripes or other data storage media affixed to it. As noted above, embodiments of the invention involve sandwiching the carbon fiber substructure 10 approximately 10 mils or less in thickness (i.e., approximately one-third of the overall thickness of the card) between two sheets 18 of clear plastic, such as clear PVC, each approximately 10 mils or less in thickness, so that the overall thickness of the transaction card is approximately 30 mils.

(22) In addition, embodiments of the invention include a thin over-laminate 24 of clear plastic, such as PVC film, applied to the outer surface 22 of each of the clear sheets 18 of the inner core 20 of the card 26. In any event, the total thickness of the card 26 for embodiments of the invention meets all standards applicable to conventional financial transaction cards, such as the foregoing thickness requirement. Further, although the outer layers 18 of the transaction card 26 for embodiments of the invention are transparent, the carbon fiber substructure 10 sandwiched between the transparent, tinted transparent, or in combination with opaque outer layers 18 is opaque to visible or infrared light, which likewise meets all standards applicable to credit cards.

(23) Various embodiments of the invention have been described in fulfillment of the various objects of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention.