Durable dual interface metal transaction cards
Apparatus and method for producing contact, contactless and dual-interface metal transaction cards that provides enhanced durability and aesthetics, with increased production efficiency. The cards may include (i) a metal core subassembly comprising a metal layer or layers (metal inlay) having a slit (S) allowing for contactless functionality, and (ii) a UV hard coat on a release-carrier layer disposed on one or both sides of the metal core subassembly, and (iii) everything may be laminated together in a single step, providing a metal face smartcard. The hard coat provides a durable, scratch-resistant surface, and protects underlying layers while allowing the passage of a laser beam to write on or within the underlying layer(s), such as a transparent laser-reactive layer. Techniques for hiding or camouflaging the slit provide a more aesthetically pleasing appearance to the metal transaction card.
1. A smartcard comprising a stackup of:
a metal component which is a metal core or a metal face for the card, said metal component comprising one or more metal layers layer(s) having a slit enabling contactless functionality of the card, and wherein the metal component has a top side and a bottom side; and
a protective layer which is UV hard coat (film) or a hard coating (screen-printed lacquer/ink/varnish) layer disposed over and protecting the metal component;
further comprising:
a front transparent laser-reactive layer with printed information and graphics disposed on the top side of the metal component, between the protective layer and the metal component; and
a rear plastic laser-reactive layer with printed information and graphics disposed on the bottom side of the metal component.
2. The smartcard of claim 1 , wherein:
the protective layer is laser-reactive.
3. The smartcard of claim 1 , wherein:
when the stackup for the card is laminated, the protective layer imparts a non-scratch gloss or matte finish to the front transparent laser-reactive layer.
4. The smartcard of claim 1 , wherein:
the front transparent laser-reactive layer has an adhesive backing and comprises a plastic layer of clear PVC, PC or PETG or any suitable synthetic material which is receptive to digital printing on its reverse side.
5. The smartcard of claim 1 , wherein:
the front transparent laser-reactive layer with a UV hard coat layer is adapted to be personalized by a laser beam, without damaging the hard coat layer during the laser etching process.
6. The smartcard of claim 1 , wherein:
the rear plastic laser-reactive layer is transparent, translucent, white or colored PVC, PC, PETG or any suitable synthetic material which is receptive to ink, and includes a magnetic stripe.
7. The smartcard of claim 1 , wherein:
the metal component includes a baked-on coating of primer, ink and a finish which camouflages the slit.
8. The smartcard of claim 1 , wherein:
the protective layer is a UV hard coat layer supported by a release-carrier layer which is removed after the layers are laminated together to form a completed assembly.
9. The smartcard of claim 1 , further comprising:
a transponder chip module (TCM) having a chip and an antenna configured to couple with the metal component so as to enable radio frequency communication with a contactless point of sale terminal.
10. A method of manufacturing a smartcard, comprising:
providing a metal core comprising at least one metal layer having a slit and an opening for a transponder chip module;
disposing a front plastic layer on a front surface of the metal core;
disposing a rear plastic layer on a rear surface of the metal core;
disposing a hard coat layer which is carried by a release-carrier layer on one or both of the front and rear plastic layers; and
laminating the metal core, front plastic layer, rear plastic layer and hard coat layer(s) on release-carrier layer(s) in a single laminating step.
11. The method of claim 10 , wherein:
the laminating step is performed at a predetermined temperature, pressure and dwell time such that the hard coat layer imparts a protective finish to the front or rear surface(s) of the card.
12. The method of claim 10 , further comprising:
after laminating, removing the release-carrier layer.
13. The method of claim 10 , further comprising:
providing a number of clear PVC layers in a stackup for the card construction; and
selectively exposing portions of the clear PVC layers to a laser beam for the engraving of card credentials.
14. The method of claim 10 , further comprising:
providing a magnetic strip and security elements a back surface of the card.
15. The method of claim 10 , further comprising:
providing graphics for camouflaging the presence of a slit in the metal layer or layers.
16. The method of claim 10 , further comprising:
a transponder chip module having at least contactless capability disposed in the card.