Transaction card incorporating aluminum alloys
View Patent ↗Disclosed are examples of transaction cards incorporating aluminum or aluminum alloys. The aluminum can be extracted or recycled from a retired aircraft. Other materials can also be incorporated into the transaction card to provide sufficient weight and rigidity to the transaction card. Polyvinyl chloride can be incorporated into the construction of the card in combination with aluminum to provide a desired user experience.
1 . A card, comprising:
an aluminum layer;
a first polyvinyl chloride layer (PVC) layer adjacent to the aluminum layer;
a second PVC layer adjacent to the aluminum layer on an opposing side of the aluminum layer relative to the first PVC layer;
a chip disposed within a first cavity within the first PVC layer; and
a wireless integrated circuit disposed within a second cavity within an antenna layer, the antenna layer separated from the aluminum layer by a ferrite layer and wherein the chip is configured to wirelessly communicate with a payment terminal via the wireless integrated circuit.
2 . The card of claim 1 , wherein the first PVC layer comprises a card face printed thereon.
3 . The card of claim 1 , wherein the second PVC layer comprises a card backing printed thereon.
4 . The card of claim 1 , wherein the aluminum layer comprises 2024-T3 aluminum alloy.
5 . The card of claim 1 , wherein the aluminum layer has a thickness less than 760 microns and is tempered.
6 . The card of claim 1 , further comprising a magnetic stripe layer adjacent to the second PVC layer on an opposing side relative to the aluminum layer, wherein the magnetic stripe layer comprises a magnetic stripe in which transaction card data is encoded.
7 . The card of claim 1 , wherein the chip implements a version of the Europay-Mastercard-Visa (EMV) standard.
8 . A method, comprising:
obtaining a portion of aluminum recycled from an airframe;
fabricating an aluminum layer from the portion of aluminum;
attaching the aluminum layer to a first polyvinyl chloride layer (PVC);
attaching the aluminum layer to a second PVC layer adjacent to an opposing side relative to the first PVC layer;
placing a chip within a first cavity within the first PVC layer; and
inserting a wireless integrated circuit within a second cavity within an antenna layer, the antenna layer separated from the aluminum layer by a ferrite layer, and wherein the wireless integrated circuit is configured to wirelessly communicate with a payment terminal.
9 . The method of claim 8 , further comprising rolling the portion of aluminum to a thickness of less than 760 microns.
10 . The method of claim 8 , further comprising attaching a rear laminate layer adjacent to the second PVC layer on an opposing side relative to the ferrite layer, wherein the rear laminate layer comprises a magnetic stripe in which transaction card data is encoded.
11 . The method of claim 8 , wherein fabricating the aluminum layer from the portion of aluminum further comprises cutting an ID-1 compliant sized piece of aluminum from the portion of aluminum.
12 . The method of claim 8 , wherein the aluminum layer comprises 2024-T3 aluminum alloy.
13 . The method of claim 8 , wherein the first PVC layer comprises a card face printed thereon, and wherein the second PVC layer comprises a card backing printed thereon.
14 . A card, comprising:
an aluminum layer;
a first polyvinyl chloride layer (PVC) layer adjacent to the aluminum layer;
an integrated circuit secured using an adhesive to the first PVC layer;
a second PVC layer adjacent to the aluminum layer on an opposing side of the aluminum layer relative to the first PVC layer; and
a chip disposed within an angled slot cut into the aluminum layer, wherein the aluminum layer is used as an antenna.
15 . The card of claim 14 , wherein the first PVC layer comprises a card face printed thereon.
16 . The card of claim 14 , wherein the second PVC layer comprises a card backing printed thereon.
17 . The card of claim 14 , wherein the aluminum layer comprises 2024-T3 aluminum alloy.
18 . The card of claim 17 , wherein the aluminum layer has a thickness less than 760 microns and is tempered.
19 . The card of claim 14 , further comprising a magnetic stripe layer adjacent to the second PVC layer on an opposing side relative to the aluminum layer, wherein the magnetic stripe layer comprises a magnetic stripe in which transaction card data is encoded.
20 . The card of claim 14 , wherein the chip implements a version of the Europay-Mastercard-Visa (EMV) standard.