Abstract: Smartcard (SC) having a metal card body (MCB) which is a coupling frame (CF) with a slit (S), and a coupling loop antenna/structure (CLA, CLS) connected to termination points (TP) on each side of the slit (S) and coupled with the module antenna (MA) of a transponder chip module (TCM). A portion of the card body (CB) may be metal and another, coplanar portion of the card body may be a synthetic material which may be transparent or translucent. Currents may be collected from the interface between the two portions. The card body (CB) may have two metal layers of different materials, adhesively joined to each other using a thermosetting epoxy that converts from B-stage to C-stage during lamination.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: (i) Smartcards (SC) manufactured from a web of metal inlays (MI; FIGS. 12-14) 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. 10-12). (ii) Printing and coating techniques may be used to camouflage the slit (FIGS. 9A-9D). (iii) Surface currents may be collected from one location in a card body (CB) and transported to another location (FIGS. 15AB). 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).

Abstract: 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.

Abstract: 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.

Abstract: 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, SCF) and (iii) a discontinuous metal frame (DMF) assembled to the metal card body (MCB) in a peripheral area thereof and having a slit (S, SDMF). 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.

Abstract: 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).

Abstract: A system and method for producing a multi-layered materials sheet that can be separated into a number of payment cards having an embedded metal layer that provides durability and aesthetics at a reduced cost and increased efficiency. During product of the materials sheet, multiple layers are collated and laminated to produce a large materials sheet. The lamination step involves heating and cooling the materials at specific temperatures and pressures for specific time periods. At a registration step, the sheet is automatically milled with alignment holes. During a singulation step, the alignment holes are used to position the sheet on a vacuum table, and vacuum holds the sheet in place while a milling device cuts cards from the sheet.