Abstract: A metal surface card in which the metal surface is formed by a metal insert configured to be retained by interlocking shapes of the metal insert and molded polymer material sandwiched between the metal insert and an opposing surface of the card which is not metal.

Abstract: A method of interlaying a metal core for a dual-layer electronic metal payment card. The metal core includes a metal layer having one or more openings formed therein (such as to receive a payment module or another electronic component or aesthetic feature). To interlay the metal core, the metal layer is laminated with a heat activated film layer and a release liner, and the laminated structure is subsequently placed on a heating plate. A polymer is applied only to the one or more openings. Using a containment structure placed over the metal core layer and a combination of heat, vacuum pressure, and pressurized inert gas, the method includes adhering and curing the polymer to the heat activated film to complete the lamination process. After curing, excess polymer is removed via a finishing edge (such as a grinder, a sander, a milling machine, or as similar edge).

Abstract: An electronic core for a metal card, such as a transaction card, having a metal core and a cured polymer top surface, is manufactured by a process in which a two-part polymer mixture is introduced to a reservoir holding the metal core in a process chamber, and then a partial vacuum followed by pressurization with inert gas are used to reduce the volume of voids in the partially-cured polymer mixture, followed by curing outside of the process chamber, and then the top surface is removed by a treatment operation, such as milling or etching, to form a reduced upper surface with less surface irregularities which is more substantially plan the original top surface.

Abstract: A method of interlaying a metal core for a dual-layer electronic metal payment card. The metal core includes a metal layer having one or more openings formed therein (such as to receive a payment module or another electronic component or aesthetic feature). To interlay the metal core, the metal layer is laminated with a heat activated film layer and a release liner, and the laminated structure is subsequently placed on a heating plate. A polymer is applied only to the one or more openings. Using a containment structure placed over the metal core layer and a combination of heat, vacuum pressure, and pressurized inert gas, the method includes adhering and curing the polymer to the heat activated film to complete the lamination process. After curing, excess polymer is removed via a finishing edge (such as a grinder, a sander, a milling machine, or as similar edge).

Abstract: Antenna and power control electrical circuits are configured for use with an initialization antenna for activating and personalizing an electronic core for electronic cards. When the antenna receives an RF signal, it turns on the power and redirects additional signals to a CPU. If the signal is validated, personalization information can be downloaded or self-diagnostic QC software can be activated; if a signal is not validated, the control circuits are reset. Once initialization is completed, the antenna control circuit is deactivated, and the power control circuit electrically connects the batter to the CPU.

Abstract: An electronic core for a metal card, such as a transaction card, having a metal core and a cured polymer top surface, is manufactured by a process in which a two-part polymer mixture is introduced to a reservoir holding the metal core in a process chamber, and then a partial vacuum followed by pressurization with inert gas are used to reduce the volume of voids in the partially-cured polymer mixture, followed by curing outside of the process chamber, and then the top surface is removed by a treatment operation, such as milling or etching, to form a reduced upper surface with less surface irregularities which is more substantially plan the original top surface.

Abstract: A metal surface card in which the metal surface is formed by a metal insert configured to be retained by interlocking shapes of the metal insert and molded polymer material sandwiched between the metal insert and an opposing surface of the card which is not metal.

Abstract: Antenna and power control electrical circuits are configured for use with an initialization antenna for activating and personalizing an electronic core for electronic cards. When the antenna receives an RF signal, it turns on the power and redirects additional signals to a CPU. If the signal is validated, personalization information can be downloaded or self-diagnostic QC software can be activated; if a signal is not validated, the control circuits are reset. Once initialization is completed, the antenna control circuit is deactivated, and the power control circuit electrically connects the batter to the CPU.