Payment card system and method
Embodiments of the invention relate to payment cards and methods for making payment cards. In one embodiment, a card comprises a first layer and a second layer adjacent to the first layer. The second layer comprises a plurality of particles comprising metal, and the plurality of particles comprise at least about 15 volume % of the second layer. In another embodiment, a mixture is prepared comprising polymer and a plurality of particles comprising metal. The plurality of particles comprise at least about 15 volume % of the mixture. The mixture is pressed and an outer layer is applied. The mixture and outer layer are then cut to form the card.
1. A card comprising:
a composite layer comprising a polymer and a plurality of particles, wherein each of the plurality of particles comprises:
a core comprising a metal; and
an outer coating comprising an insulator, wherein the plurality of particles comprise at least about 15 volume % of the composite layer, and wherein the composite layer is less susceptible to electrostatic buildup than the metal.
2. The card of claim 1 , wherein the insulator comprises a dielectric material.
3. The card of claim 2 , wherein the dielectric material is an inorganic material selected from the group consisting of metal oxides, metal nitrides, and metal carbides.
4. The card of claim 2 , wherein the dielectric material is an organic material selected from the group consisting of epoxy, epoxy-acrylate, and polyimide.
5. The card of claim 1 , wherein the coating has a thickness of less than about 100 microns.
6. The card of claim 5 , wherein the coating has a thickness of less than about 50 microns.
7. The card of claim 1 , wherein the metal is selected from the group consisting of W, Cu, Ni, Fe, Au, Ag, Al, Pt, steel, and bronze.
8. The card of claim 7 , wherein the metal is W.
9. The card of claim 1 , wherein the polymer is selected from the group consisting of polyvinyl chloride, polyvinyl chloride acetate, polyethylene teraphthalate, polybutylene terephthalate, polycarbonate, and polypropylene.
10. The card of claim 9 , wherein the polymer is polyvinyl chloride.
11. The card of claim 1 , further comprising a magnetic stripe and a contactless element.
12. The card of claim 1 , wherein the card is characterized by:
a length of about 86 mm;
a width of about 54 mm; and
a thickness of about 0.7 to 0.9 mm.
13. A method for making a card, the method comprising:
preparing a mixture comprising a polymer and a plurality of particles, wherein each of the plurality of particles comprises:
a core comprising a metal; and
an outer coating comprising an insulator;
pressing the mixture to form a composite layer comprising the polymer and the plurality of particles, wherein the plurality of particles comprise at least about 15 volume % of the composite layer, and wherein the composite layer is less susceptible to electrostatic discharge than the metal; and
cutting the composite layer to form the card.
14. The method of claim 13 , wherein the insulator comprises a dielectric material selected from the group consisting of metal oxides, metal nitrides, metal carbides, epoxy, epoxy-acrylate, and polyimide.
15. The method of claim 13 , further comprising:
prior to preparing the mixture, depositing the outer coating comprising the insulator on the cores comprising the metal.
16. The method of claim 15 , wherein depositing the outer coating includes a deposition process selected from the group consisting of chemical vapor deposition, anodic coating processes, and cathodic coating processes.
17. The method of claim 13 , wherein the mixture further comprises at least one of a plasticizer and a thermal stabilizer.
18. The method of claim 13 , wherein the mixture is prepared at a process temperature of about 120 to 200 ° C.
19. The method of claim 13 , wherein the mixture is pressed at a pressure of about 5 to 20 tons per square foot.
20. The method of claim 13 , further comprising:
adding a magnetic stripe and a contactless element to the card.