Dual interface metal cards and methods of manufacturing
(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. 9 A- 9 D). (iii) Surface currents may be collected from one location in a card body (CB) and transported to another location (FIGS. 15 AB). 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).
1. A smartcard (SC) comprising:
a transponder chip module (TCM) having a module antenna (MA) for enabling contactless capability and contact pads (CP) for effecting a contact interface;
a card body (CB) having a module opening (MO) for receiving the transponder chip module (TCM) and a slit (S) extending from a peripheral edge of the card body towards an interior area of the card body; and
a flexible circuit (FC) having a coupling loop structure (CLS) with an antenna structure (AS) disposed near the transponder chip module for coupling with the module antenna;
wherein:
the smartcard (SC) comprises a front card body (FCB);
a smaller rear card body (RCB) fits into a recess in a rear surface of the front card body (FCB); and
wherein:
the coupling loop structure (CLS) is disposed on the rear card body (RCB).
2. The smartcard of claim 1 , wherein:
the rear card body comprises a layer of an insulating material.
3. The smartcard of claim 1 , wherein:
the coupling loop structure (CLS) comprises two antenna structures (AS 1 , AS 2 ).
4. The smartcard of claim 2 , wherein:
the two antenna structures (AS) couple with the slit (S) and the module antenna (MA).
5. The smartcard of claim 1 , wherein:
the coupling loop structure (CLS) is disposed on a flexible circuit (FC) which is a flexible substrate with conductive traces.
6. The smartcard of claim 1 , wherein:
the antenna structure is wire wound, chemically etched or laser etched.
7. The smartcard (SC) of claim 1 , wherein:
the card body is a metal card body (MCB).
8. The smartcard (SC) of claim 1 , wherein:
the flexible circuit (FC) is connected to termination points (TP) near the slit.
9. The smartcard (SC) of claim 1 , further comprising:
a patch antenna (PA) disposed near or overlying the slit.
10. The smartcard (SC) of claim 1 , wherein:
the smartcard is a metal card, composite metal card, or encapsulated metal card.
11. The smartcard (SC) of claim 1 , wherein:
the transponder chip module has 6 or 8 contact pads.
12. The smartcard (SC) of claim 1 , wherein:
the front card body (FCB) comprises an anodized metal layer (ML) with the slit (S); and
the contact pads (CP) protrude through a plurality of individual openings in the anodized metal layer.