Laminated cards with manual input interfaces

• US 8,757,499 B2
• Filed: 09/10/2012
• Issued: 06/24/2014
• Est. Priority Date: 04/06/2009
• Status: Active Grant

• Current Assignee: Dynamics Inc.
• Original Assignee: Dynamics Inc.
• Inventors: Cloutier, Bruce S., Mullen, Jeffrey D.
• Primary Examiner(s): Kim, Ahshik
• Application Number:
  US13/607,979
• Publication Number:
  US 20120326013A1
• Time in Patent Office: 652 Days
• Field of Search: 235/488, 235/492, 235/449, 235/451
• US Class Current: 235/488
• CPC Class Codes: G06K 19/06196 Constructional details
• CPC Class Codes: G06K 19/07701 the record carrier comprising an interface suitable for human interaction
• CPC Class Codes: G06K 19/07707 the visual interface being a display, e.g. LCD or electronic ink
• CPC Class Codes: G06K 19/07745 Mounting details of integrated circuit chips
• CPC Class Codes: G07F 7/0833 Card having specific functional components

Abstract

A laminated card is provided with manual input interfaces. Such manual input interfaces may provide tactile feedback to a user. Laminated cards may be provided as payment cards, identification cards, medical cards, or any other type of card.

Claims

1. A method of fabricating a card, comprising:

providing a first layer of polymer;

providing a second layer of polymer;

providing a flexible circuit board between the first and second layers;

providing a material including at least one manual user interface between the first and second layers, the at least one manual user interface inside the material;

providing a soft laminate between the first and second layers, the material separating the laminate from the at least one manual user interface; and

hardening the laminate.

2. The method of claim 1, wherein the shape of the material is one of a cylindrical shape, a cubic shape and a rectangular prism shape.

3. The method of claim 1, wherein the material is adhered to one of

the flexible circuit board, and

each of the first and second layers.

4. The method of claim 1, wherein the soft laminate is in liquid form.

5. The method of claim 1, wherein the material provides an enclosed cavity, and during the injecting a soft laminate, the soft laminate does not enter the enclosed cavity.

6. The method of claim 1, wherein the at least one manual user interface is at least one of a mechanical switch, a capacitive switch and a light switch.

7. The method of claim 1, wherein the at least one manual user interface is at least one of a dome switch, a piezoelectric switch, a capacitive touch sensor and a light sensor.

8. A method of fabricating a card, comprising:

providing a first layer of polymer;

providing a second layer of polymer;

providing a flexible circuit board between the first and second layers;

providing a plurality of blocking materials between the first and second layers;

providing a manual user interface between the first and second layers, and between the plurality of blocking materials; and

injecting a soft laminate between the first and second layers, the plurality of blocking materials separating the laminate from the manual user interface; and

hardening the laminate.

9. The method of claim 8, wherein the blocking materials are adhered to at least one of the flexible circuit board, and each of the first and second layers.

10. The method of claim 8, wherein the soft laminate is in liquid form.

11. The method of claim 8, wherein the blocking materials, and the first and second layers, provide an enclosed cavity, and

during the injecting a soft laminate, the soft laminate does not enter the enclosed cavity.

12. The method of claim 8, wherein the blocking materials, and the first and second layers, provide an enclosed cavity,

the at least one manual user interface is a plurality of manual user interfaces, and

the plurality of manual user interfaces includes at least a mechanical switch and a capacitive switch.

13. The method of claim 8, wherein the at least one manual user interface is at least one of a dome switch, a piezoelectric switch, a capacitive touch sensor and a light sensor.

14. The method of claim 8, wherein the blocking materials are adhered to only one of the first and second layers.

15. A card, comprising:

a first layer;

a second layer on the first layer;

a flexible circuit board between the first and second layers;

a material including at least one manual user interface between the first and second layers, the at least one manual user interface inside the material;

a laminate between the first and second layers, the material separating the laminate from the at least one manual user interface; and

a first light sensor on the flexible circuit board.

16. The card of claim 15, comprising:

a second light sensor on the flexible circuit board.

17. The card of claim 15, wherein the first light sensor is electrically coupled to the flexible circuit board.

18. The card of claim 15, wherein the first light sensor is one of surface mounted to the flexible circuit board, wire-bonded to the flexible circuit board and electrically coupled to the flexible circuit board in a flip-chip configuration.

19. The card of claim 15, comprising:

a processor coupled to the first light sensor.

20. The card of claim 15, comprising:

at least one light blocker adjacent to the first light sensor.