Multi-metal layered card
View Patent ↗A metal transaction card is provided having a metal core layer with metal cladding layers connected thereto on opposing sides thereof. The metal core layer may have a density and/or thickness that is significantly greater than the density and/or thickness of the metal cladding layers. The density of the metal core layer may be at least 2.5 times greater than the density of the metal cladding layers. The density of the metal core layer may be at least 7.5. The outward facing lateral surface of one or both of the metal cladding layers may be anodized, or anodized and colorized. The anodized lateral surface(s) may be coated to increase the performance of a one or more hot-stamped elements attached to the coated surface(s).
1. A method for producing a transaction card, comprising:
connecting a first metal cladding layer and a second metal cladding layer to opposing sides of a metal core layer to form a metal-clad core having outward-facing, lateral surfaces on opposing sides thereof, wherein the metal core layer has a first density value, wherein the first metal cladding layer and the second metal cladding layer each have densities no greater than a second density value, and wherein said first density value is at least 2.5 times greater than said second density value; and,
defining visible indicium indicative of an account associated with the transaction card after said connecting step, said visible indicium being on one side of said metal-clad core.
2. A method according to claim 1 , further comprising:
anodizing at least one of said outward-facing lateral surfaces of said metal-clad core after said connecting step to define an anodized lateral surface.
3. A method according to claim 2 , further comprising:
coating said anodized lateral surface to define a coated, anodized lateral surface.
4. A method according to claim 3 , further comprising:
attaching a card element to the coated, anodized lateral surface.
5. A method according to claim 4 , said attaching step comprising:
hot-stamping said at least one card element directly to said coated, anodized lateral surface.
6. A method according to claim 5 , wherein said hot-stamped element comprises at least one of a machine readable element, a card holder signature panel, a hologram element, and a decorative element.
7. A method according to claim 3 , wherein said coating is light transmissive.
8. A method according to claim 3 , wherein said transaction card has a total thickness across said metal core layer, first metal cladding layer, second metal cladding layer and coating, and wherein said metal core layer defines at least 30% of said total thickness, and said first metal cladding layer and said second metal cladding layer combinatively define no greater than 70% of said total thickness.
9. A method according to claim 2 , said defining step comprising:
laser etched removal of a portion of the anodized, lateral surface of said at least one of said first and second metal cladding layers.
10. A method according to claim 1 , further comprising:
anodizing at least one of said outward-facing lateral surfaces of said metal-clad core after said connecting steps to define an anodized lateral surface;
coating said anodized lateral surface to define a coated, anodized lateral surface; and,
attaching a card element to the coated, anodized lateral surface.
11. A method according to claim 10 , wherein said anodizing step includes colorization of said anodized lateral surface.
12. A method according to claim 1 , wherein said connecting step comprises:
applying an adhesive to at least one outward facing surface of the metal core layer, or at least one inward facing surface of the first metal cladding layer or second metal cladding layer.
13. A method according to claim 1 , wherein said connecting step comprises:
utilizing a plating process.
14. A method according claim 1 , wherein said first density value is at least 5.0 times greater than said second density value.
15. A method according to claim 1 , further comprising:
coating an outer facing lateral surface of the metal-clad core on said one side of the metal-clad core.
16. A method according to claim 15 , said defining step comprising:
ink jet printing said visible indicium indicative of an account after said coating step.
17. A method according to claim 15 , said defining step comprising:
etching said visible indicium indicative of an account after said coating step.
18. A method according to claim 1 , wherein a total weight of the metal core layer is at least 50% of a total weight of the transaction card.
19. A method according to claim 1 , wherein said first density value is at least 7 g/cm 3 .
20. A method according to claim 1 , wherein said metal core layer comprises a metal from the following group: tungsten, stainless steel, copper, silver, gold, or alloys comprising one or more of such metals; and,
wherein at least one of the first metal cladding layer and second metal cladding layer comprises at least one metal from the following group: aluminum, titanium, zinc, niobium, tantalum, or alloys comprising one or more of such metals.