Transaction card assembly and methods of manufacture

• US 8,690,064 B2
• Filed: 04/30/2009
• Issued: 04/08/2014
• Est. Priority Date: 04/30/2009
• Status: Expired due to Fees

• Current Assignee: Abnote USA Incorporated (American Banknote Corporation)
• Original Assignee: Abnote USA Incorporated (American Banknote Corporation)
• Inventors: Goldstein, Keith E., Cageao, Ronald A.
• Primary Examiner(s): Lee, Michael G
• Assistant Examiner(s): CHEDEKEL, TABITHA F
• Application Number:
  US12/433,043
• Publication Number:
  US 20100276495A1
• Time in Patent Office: 1,804 Days
• Field of Search: 235/492, 235/487, 257/678, 257/679, 257/684, 257/687, 257/713
• US Class Current: 235/492
• CPC Class Codes: B29C 44/1228 Joining preformed parts by the expanding material
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/485 Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
• CPC Class Codes: B29C 65/4865 containing additives C09J11/00 and subgroups take precedence
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2017/00 Carriers for sound or information
• CPC Class Codes: B29L 2031/744 Labels, badges, e.g. marker sleeves
• CPC Class Codes: B32B 2305/342 Chips
• CPC Class Codes: B32B 2305/347 Security elements
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2425/00 Cards, e.g. identity cards, credit cards
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 38/04 Punching, slitting or perforating
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B42D 2033/30 Plastic material
• CPC Class Codes: B42D 2033/40 with a foldable or removable part
• CPC Class Codes: B42D 2033/46 : with electrical circuitry
• CPC Class Codes: B42D 25/00 : Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof printing processes to produce identification or security features B41M3/14
• CPC Class Codes: B42D 25/285 : Gift cards
• CPC Class Codes: B42D 25/305 : Associated digital information record carriers for use with machines and with at least a part designed to carry digital markings G06K19/00
• CPC Class Codes: B42D 25/309 : Photographs
• CPC Class Codes: B42D 25/328 : Diffraction gratings; Holograms
• CPC Class Codes: B42D 25/369 : Magnetised or magnetisable materials
• CPC Class Codes: B42D 25/47 : using adhesives
• CPC Class Codes: C09J 2400/226 : in the substrate
• CPC Class Codes: C09J 2475/00 : Presence of polyurethane
• CPC Class Codes: C09J 5/08 : using foamed adhesives
• CPC Class Codes: G06K 19/02 : characterised by the selection of materials, e.g. to avoid wear during transport through the machine
• CPC Class Codes: G06K 19/06 : characterised by the kind of the digital marking, e.g. shape, nature, code

Abstract

A transaction card assembly may be constructed and arranged for use in a transaction by an issuee of the transaction card assembly. The transaction card assembly may include a first layer including a sheet of material, a second layer including a sheet of material, and an adhesive foam material between the first and second layers that expands to fill a space between the first and second layers and to define, at least in part, a finished thickness for the transaction card assembly and bonds the first and second layers together. Indicia, such as information representing an account number, biometric data representing a feature of the issuee, etc., may be included with the assembly for use in a transaction.

Claims

1. A transaction card assembly constructed and arranged for use in a transaction by an issuee of the transaction card assembly, comprising:

a first layer including a sheet of material comprising a top surface, a bottom surface and a plurality of peripheral side surfaces, the entirety of at least one of the peripheral side surfaces for the first layer being externally exposed;

a second layer including a sheet of material comprising a top surface, a bottom surface and a plurality of peripheral side surfaces, the entirety of at least one of the peripheral side surfaces for the second layer being externally exposed;

a semiconductor device located at least partially between the first and second layers;

an adhesive foam material between the first and second layers, the adhesive foam material expanding to fill a space between the first and second layers and to define, at least in part, a finished thickness for the transaction card assembly, the adhesive foam material at least partially encapsulating the semiconductor device and bonding the bottom surface of the first layer to the top surface of the second layer; and

indicia attached to the first and second layers and the adhesive foam material that is interacted with in a transaction regarding the transaction card assembly.

2. The assembly of claim 1, wherein the first and second layers each include a sheet of polymer material having a thickness of less than 0.030 inches.

3. The assembly of claim 2, wherein the finished thickness of the transaction card assembly is about 0.030 inches.

4. The assembly of claim 1, wherein the transaction card assembly is constructed and arranged to meet ANSI and ISO standards for a CR-80 card.

5. The assembly of claim 1 wherein the indicia includes information stored in the semiconductor device.

6. The assembly of claim 5, wherein the semiconductor device is constructed and arranged to receive and/or send radio frequency communications with a device located at a distance from the transaction card assembly.

7. The assembly of claim 5, wherein the transaction card assembly is constructed and arranged to function as a smartcard.

8. The assembly of claim 1, wherein the indicia includes one or more of the following:

an alphanumeric string formed on the first or second layer;

information encoded in a magnetic strip on the first or second layer;

a barcode formed on the first or second layer;

graphical information printed on the first or second layer;

an image of a person formed on the first or second layer;

a hologram;

a PIN formed on the first or second layer;

a removable label adhered to the first or second layer that carries printed alphanumeric text or a symbol;

or

a credit card security code.

9. The assembly of claim 1, wherein the first and second layers define opposite substantially planar sides of the transaction card assembly.

10. The assembly of claim 1, wherein the indicia includes a machine-readable feature arranged to be read by a device separate from the transaction card assembly.

11. The assembly of claim 10, wherein reading of the machine-readable feature obtains information representing an account associated with the transaction card assembly.

12. The assembly of claim 1, wherein the first layer and/or the second layer include a line of weakness arranged to permit separation of two portions of the transaction card assembly at the line of weakness without tools.

13. The assembly of claim 1, wherein the two portions of the transaction card assembly include an auxiliary portion and a CR-80 card portion.

14. The assembly of claim 13, wherein the auxiliary portion includes indicia arranged for use in a purchase of goods or services.

15. The assembly of claim 13, wherein the assembly includes a gift card, a prepaid phone card, a frequent shopper card, a loyalty card, a credit/debit card, or a membership card.

16. The assembly of claim 1, wherein the adhesive foam includes a polyurethane foam including a reaction product of:

at least one isocyanate;

at least one isocyanate-reactive component; and

water,

optionally in the presence of at least one of blowing agents, surfactants, cross-linking agents, extending agents, pigments, flame retardants, catalysts and fillers.

17. The assembly of claim 16, wherein the polyurethane foam has a free rise density of from about 5 lb/ft³ to about 25 lb/ft³, a reactive cream time of from about 10 seconds to about 120 seconds, and an elongation of from about 30% to about 300%.

18. The assembly of claim 1, wherein the first and second layers each have a thickness of from about 0.01 in. to about 0.06 in.

19. A method for producing a transaction card assembly constructed and arranged for use in a transaction by an issuee of the transaction card assembly, the method comprising:

providing a first layer including a sheet of material comprising an inner surface, an outer surface and a plurality of side surfaces;

applying an adhesive foam onto the inner surface of the first layer;

providing a second layer adjacent the adhesive foam with the adhesive foam disposed between the first and second layers, the second layer including a sheet of material comprising an inner surface, an outer surface and a plurality of side surfaces;

providing a semiconductor device, the semiconductor device being positioned at least partially between the inner surfaces of the first and second layers;

expanding the adhesive foam between the first and second layers so as to fill a space between the first and second layers and define, at least in part, a finished thickness of the transaction card assembly, the adhesive foam at least partially encapsulating the semiconductor device;

curing the adhesive foam to bond the inner surfaces of the first and second layers together and thereby form a unitary device;

cutting through the first layer, second layer and adhesive layer of the unitary device to yield a transaction card assembly, the entirety of at least one of the peripheral side surfaces for each of the first and second layers being externally exposed; and

providing indicia associated with the first and second layers and the adhesive foam that is interacted with in a transaction regarding the transaction card assembly.

20. The method of claim 19, wherein the first and second layers each include a sheet of polymer material having a thickness of less than 0.030 inches.

21. The method of claim 19, wherein the finished thickness of the transaction card assembly is about 0.030 inches.

22. The method of claim 19, further comprising:

producing a CR-80 card from the assembly of the first and second layers, the adhesive foam and the indicia, wherein the CR-80 card is constructed and arranged to meet ANSI and ISO standards.

23. The method of claim 19 wherein the indicia includes information stored in the semiconductor device.

24. The method of claim 23, wherein the semiconductor device is constructed and arranged to receive and/or send radio frequency communications with a device located at a distance from the transaction card assembly.

25. The method of claim 24, wherein the transaction card assembly is constructed and arranged to function as a smartcard.

26. The method of claim 19, wherein the indicia includes one or more of the following:

an alphanumeric string formed on the first or second layer;

information encoded in a magnetic strip on the first or second layer;

a barcode formed on the first or second layer;

graphical information printed on the first or second layer;

an image of a person formed on the first or second layer;

a hologram;

a PIN formed on the first or second layer;

a removable label adhered to the first or second layer that carries printed alphanumeric text or a symbol;

or

a credit card security code.

27. The method of claim 19, wherein the first and second layers define opposite substantially planar sides of the transaction card assembly.

28. The method of claim 19, wherein the indicia includes a machine-readable feature arranged to be read by a device separate from the transaction card assembly.

29. The method of claim 28, wherein reading of the machine-readable feature obtains information representing an account associated with the transaction card assembly.

30. The method of claim 19, wherein the first layer and/or the second layer include a line of weakness arranged to permit separation of two portions of the transaction card assembly at the line of weakness without tools.

31. The method of claim 19, wherein the two portions of the transaction card assembly include an auxiliary portion and a CR-80 card portion.

32. The method of claim 31, wherein the auxiliary portion includes indicia arranged for use in a purchase of goods or services.

33. The method of claim 32, wherein the assembly includes a gift card, a prepaid phone card, a frequent shopper card, a loyalty card, a credit/debit card, or a membership card.

34. The method of claim 19, wherein the adhesive foam includes a polyurethane foam including a reaction product of:

at least one isocyanate;

at least one isocyanate-reactive component; and

water,

optionally in the presence of at least one of blowing agents, surfactants, cross-linking agents, extending agents, pigments, flame retardants, catalysts and fillers.

35. The method of claim 34, wherein the polyurethane foam has a free rise density of from about 5 lb/ft³ to about 25 lb/ft³, a reactive cream time of from about 10 seconds to about 120 seconds, and an elongation of from about 30% to about 300%.

36. The method of claim 19, wherein the first and second layers each have a thickness of from about 0.01 in. to about 0.06 in.