Systems and methods for producing non-standard shaped cards

Patent metadata

Field	Value
Publication number	US-12367368-B2
Application number	US-202418670981-A
Country	US
Kind code	B2
Filing date	May 22, 2024
Priority date	Jan 3, 2020
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

Abstract

Example embodiments of systems and methods for card production are provided. A card may include processing circuitry including a chip and memory. The card may include one or more antennas in communication with the chip. The card may include a first layer of material aligned within a perimeter of the card via laminate encapsulation. The first layer of material may comprise a non-rectangular shape. The first layer of material may be offset with a shape of the card. The first layer of material may be in communication with the chip. The first layer of material may comprise at least one selected from the group of steel, tungsten, titanium, or any combination thereof. The card may be compliant with one or more form factors.

First claim

What is claimed is:

1. A method, comprising:
providing a card having a first layer comprising a non-rectangular slug, the slug including at least one aperture configured to house a contact pad;
performing a laminate encapsulation of the slug to the card,
wherein the slug is disposed within a perimeter of the card, and
wherein the slug is offset with a shape of the card.

2. The method of claim 1 , wherein the non-rectangular slug includes one or more rounded corners.

3. The method of claim 1 , wherein:
the non-rectangular slug comprises a circular shape, an oval shape, an elliptical shape, a trapezoidal shape, a horseshoe shape, a bullet shape, or a door knob shape.

4. The method of claim 1 , wherein the slug comprises one selected from the group of steel, tungsten, tungsten, titanium, and any combination thereof.

5. The method of claim 1 , wherein the slug is encapsulated in laminate after personalization of the card.

6. The method of claim 5 , wherein the personalization comprises one or more of encoding data, card embossing, and printing data onto a card that is specific to a user account.

7. The method of claim 5 , wherein the personalization comprises addition of one or more images or one or more patterns.

8. The method of claim 5 , wherein the one or more images or one or more patterns are provided by a user.

9. A card, comprising:
a first layer comprising a non-rectangular slug, the slug including at least one aperture configured to house a contact pad;
a second layer comprising a laminate that encapsulates the non-rectangular slug,
wherein the non-rectangular slug is disposed within a perimeter of the card, and
wherein the slug is offset with a shape of the card.

10. The card of claim 9 , wherein the non-rectangular slug includes one or more rounded corners.

11. The card of claim 9 , wherein:
the non-rectangular slug comprises a circular shape, an oval shape, an elliptical shape, a trapezoidal shape, a horseshoe shape, a bullet shape, or a door knob shape.

12. The card of claim 9 , wherein the slug comprises one selected from the group of steel, tungsten, tungsten, titanium, and any combination thereof.

13. The card of claim 9 , wherein the slug is encapsulated in laminate after personalization of the card.

14. The card of claim 13 , wherein the personalization comprises one or more of encoding data, card embossing, and printing data onto a card that is specific to a user account.

15. The card of claim 13 , wherein the personalization comprises addition of one or more images or one or more patterns.

16. The card of claim 13 , wherein the one or more images or one or more patterns are provided by a user.

Assignees

• Capital One Services Llc

Inventors

• Herrington Daniel
• Parker Suzanne
• Garner Adrian
• Cheng Lin Ni Lisa

Classifications

• G06K19/07722

  the record carrier being multilayered, e.g. laminated sheets (flat articles in general, see B32B37/00) · CPC title

• G06K19/04

  characterised by the shape · CPC title

• G06K19/0772 Primary

  Physical layout of the record carrier · CPC title