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 first layer comprising a polymer;
a second layer adjacent to the first layer and comprising a composite, wherein the composite comprises a polymer and a plurality of particles comprising a metal, wherein the plurality of particles further comprise about 15 to 50 volume % of the second layer, and wherein the composite is less susceptible to electrostatic buildup than the metal; and
a third layer adjacent to the second layer and opposite the first layer, wherein the third layer comprises a polymer.
2. The card of claim 1 , wherein the plurality of particles further comprise an outer coating.
3. The card of claim 1 , wherein the metal comprises tungsten.
4. The card of claim 1 , wherein the polymer of the second layer comprises polyvinyl chloride.
5. The card of claim 1 , wherein the card is about 86 millimeters long, about 54 millimeters wide, and about 0.7 to 0.9 millimeters thick.
6. The card of claim 1 , wherein the card further comprises a magnetic stripe and a contactless element.
7. The card of claim 6 , wherein the card is adapted to exhibit a peak current discharge less than about 1000 milliamps when the card is charged to about 10 kilovolts and interacting with an access device.
8. The card of claim 7 , wherein the card is adapted to exhibit a discharge energy less than about 15 nanojoules when the card is charged to about 10 kilovolts, the magnetic stripe is adapted to exhibit a dynamic resistance greater than about 1 kiloohms at a peak current discharge of about 10 kilovolts, a capacitance less than about 2 picofarads, and a discharge energy of less than about 500 nanojoules when the magnetic stripe is charged to about 10 kilovolts, and the contactless element is adapted to exhibit a capacitance less than about 5 picofarads, when the card interacts with an access device.
9. A method for making a card, the method comprising:
preparing a mixture comprising:
a plurality of particles comprising a metal, wherein the plurality of particles further comprise about 15 to 50 volume % of the mixture; and
a polymer;
pressing the mixture to form a composite layer, wherein the composite layer is less susceptible to electrostatic buildup than the metal;
applying a first outer layer to a first surface of the composite layer, wherein the first outer layer comprises a polymer;
applying a second outer layer to a second surface of the composite layer, wherein the second surface is opposite the first surface of the composite layer, and wherein the second outer layer comprises a polymer; and
cutting the composite layer, the first outer layer, and the second outer layer to form the card.
10. The method of claim 9 , wherein the mixture further comprises a plasticizer and a thermal stabilizer.
11. The method of claim 9 further comprising applying an outer coating to the plurality of particles prior to preparing the mixture.
12. The method of claim 9 , wherein the metal comprises tungsten.
13. The method of claim 9 , wherein the polymer of the composite layer comprises polyvinyl chloride.
14. The method of claim 9 , wherein the mixture is prepared at a process temperature of about 120 to 200 degrees Celsius.
15. The method of claim 9 , wherein the mixture is pressed at a pressure of about 5 to 20 tons per square foot.
16. The method of claim 9 , wherein the first or second outer layer further comprises a pigment.
17. The method of claim 9 , wherein the first or second outer layer further comprises a magnetic stripe.
18. The method of claim 9 further comprising adding a contactless element to the card.