SE535875C2 - Foldable card designed to form a USB plug - Google Patents

Abstract

38 Abstract An improved foldable card is disclosed. According to theinvention, one a single hinge is arranged between a first partand a second part. This single hinge is foldable for providingsingle fold of the card. By this folding the USB plug isformed by the first part and the second part 129 together. Thethickness of a standard credit card is less than half thewidth of the USB receptacle gap. Therefore, in order toachieve a solid electrical contact between the electricalcontact means of the card and the electrical contact means ofa USB receptacle, a force providing arrangement is arrangedfor providing a repulsive force between the first part and thesecond said part when the card is folded. By this repulsiveforce, the electrical contact means is forced againstcorresponding electrical contact means of the USB receptacle when the USB plug is inserted into the USB receptacle. Fig. 1a

Description

lO FOLDABLE CARD Field of the invention The present invention relates to a card as defined in the preamble of claim l.

The present invention also relates to a manufacturing method as defined in the preamble of claim 29.

Related art and background of the invention Universal Serial Bus (USB) contacts, including USB receptaclesand USB plugs, are widely used today in connection withcomputers, and essentially all other types of electricalappliances, such as cameras, music playing devices and thelike. The USB plug is often connected to some kind of memorydevice being situated in the same device as the USB plug. Overthe years, these memory devices have become smaller and smaller in size.

Conventional USB plugs, however, have a rather large physicalsize, and are not very easily carried around by a user.Therefore, according to prior art documents, such as US7,377,448 and WO 2008/036537, credit cards have been proposedto be used as USB plugs when they are folded together. By suchfoldable credit cards providing an USB plug, the USB plug caneasily be carried around by a user in e.g. a wallet together with his other credit cards.

However, the prior art foldable USB plug credit cards have a number of problems.

One such problem is that the prior art foldable credit cardshave to be folded a number of times to free a USB plug, and to also achieve an USB plug having a thickness corresponding to lO the gap of the USB receptacle, such that the electricalcontact means of the USB plug can make contact with theelectrical contact means of the USB receptacle. To be ableachieve these multiple foldings of the card, the card has tobe provided with multiple hinges, or some other kind ofmultiple folding means. Each such hinge or folding means addsto the manufacturing costs of the credit card, and also makes the credit card more easily breakable.

Also, in many of the prior art solutions, such as the onedisclosed in US 7,377,448, the cards are folded very close tothe electrical contacts of the credit card. When cards havingsuch electrical contacts are manufactured, the cards are firstmade, e.g. by lamination. Then, an area corresponding to theelectrical contacts is milled out from the card with a cutter,and the electrical contacts are glued to the card in themilled-out area. This ways of producing the cards results inthe cards being sensitive for forces in the card close to theelectrical contacts. Typically, folding of the card causesrelatively strong forces in the material of the card around the foldings.

Thus, in close vicinity of the hinges, forces are created whenthe card is folded. Such forces may destroy the card in the sense of the electrical contacts letting loose from the card.

Also, the prior art foldable credit cards have a problem inthat the USB plugs being formed by the folded card do notcreate a very good electrical contact with the correspondingelectrical contacts of the USB receptacle. In many cases, theprior art foldable cards tend to loose their grip of the USBreceptacle, and fall out of the receptacle, thereby, ofcourse, loosing contact with the electrical contacts of the USB receptacle. lO Aim and most important features of the invention It is an object of the present invention to provide a cardbeing foldable for providing an USB plug, which solves the above stated problems.

The present invention aims to provide a more robust foldablecard than the ones known in the background art, which alsocreates better contact with the electrical contacts of the USB receptacle.

The object is achieved by the above mentioned card according to the characterizing portion of claim l.

The object is also achieved by the above mentioned manufacturing method for manufacturing according to claim 29.

By the invention, a very robust foldable card is achieved,which ensures very good contact between the electrical contact means of the created USB plug and the USB receptacle.

Also, the card can be manufactured very efficiently, which lowers the production costs.

The card according to the invention is, due to itsadvantageous single hinge concept, very easy to use. Thesingle hinge used also leaves large portions of the cardwithout having folds, which facilitates easier printing on thecard, and also facilitates printing of large images on the card.

These large portions being free from folds also make itpossible to provide the card according to the invention with more than one chip, such as one chip being connected to the lO formed USB plug, and one or more further chips being e.g. smart card chips or the like.

The card also has an advantage in that when it is folded andinserted into an USB receptacle, it does not block neighboringUSB receptacles from usage. Thus, the foldable card accordingto the invention only takes up a minimal number of USB receptacles when being used.

Also, the use of the single hinge also results in that one ofthe longer sides of the card can be left unfolded whencreating a USB plug by folding, whereby this unfolded side canbe provided with a magnetic strip. The foldable card canthereby also be used as a traditional credit card and the like.

According to an embodiment of the invention, the foldable cardis provided with a display, which can be used for authentication purposes and the like.

According to an embodiment of the invention, the single hingeis an elastic hinge being produced by injection moulding. Thiselastic hinge automatically returns into its flat positionafter being pulled out of the USB receptacle, which makes theuse of the card very easy. The feature that the hinge iselastic here, and in this document, means that the hingematerial itself is essentially not modified or transformedover time. Thus, the relations between the molecules of thematerial of the elastic hinge are here kept essentially intactover the life cycle of the card, even after the elastic has been folded a large number of times.

Also, due to the very low production costs of the cardsaccording to the invention, these cards can be produced in large quantities to be used for distribution of software, lO advertisements, invitations, or the like. The cards can easilybe sent by post, since they are very lights, or can be givenaway by hand, since they are suitable for transportation in e.g. a purse or a wallet.

In other words: According to an embodiment of the invention, an electricaldevice for use with a receptacle having internal contactsadjacent to an internal gap is presented. The device includesa card substrate with rectilinear sides and first and secondparts separated by a border obliquely oriented relative to therectilinear sides. Electrical contacts located at a first endof the first part of the card substrate are configured to matewith the internal contacts of the receptacle. The deviceincludes a resilient hinge, which is formed along the borderexternal to the electrical contacts. The hinge is configuredto bend so as to permit the second part of the card substrateto fold over the first part so that the first end of the firstpart and a corresponding second end of the second part aretogether insertable into the gap and exert an outward forcewithin the gap that holds the electrical contacts against the internal contacts of the receptacle.

According to an embodiment of the invention, a foldable carddevice, including a card having a first part and a second parthingeably connected to the first part by a single hinge ispresented. The single hinge is operative to cause the card totransition from a flat unfolded configuration to a foldedconfiguration, by folding the first part over the second partabout a single folding line, which may be continuous. A force-exerting element is provided on the card, wherein in thefolded configuration the force-exerting element applies urges the first part to move apart from the second part. An lO electrical contact is disposed on the first part of the card,wherein in the folded configuration the electrical contact anda corresponding portion of the second part define a plugassembly for insertion into an electrical receptacle to forman electrical connection therewith. The thickness of the plugassembly is less than half the width of an internal gapbetween an electrical contact of the receptacle and a wall ofthe receptacle. When the plug assembly is received by thereceptacle, the folding line is outside the receptacle, andthe repulsive force causes the electrical contact on the card to engage the electrical contact of the receptacle.

According to an embodiment of the invention, an electricaldevice for use with a receptacle having internal contactsadjacent to an internal gap is presented. The device includesa card substrate with rectilinear sides and first and secondparts separated by a border obliquely oriented relative to therectilinear sides. Electrical contacts located at a first endof the first part of the card substrate are configured to matewith the internal contacts of the receptacle. A hinge isformed along the border and is configured to bend so as topermit the second part of the card substrate to fold over thefirst part so that the first end of the first part and acorresponding second end of the second part are togetherinsertable into the gap. Protrusions are formed on at leastone of the first part and the second part, wherein in a foldedconfiguration of the card substrate, the protrusions that aredisposed on one of the first part and the second part contactanother of the first part and the second part and exert anoutward force within the gap that holds the electrical contacts against the internal contacts of the receptacle.

Further, according to an embodiment of the invention a method for manufacturing a foldable card device is presented, which lO is carried out by forming a card, forming a single hinge inthe card to hingeably connect a first part of the card to asecond part of the card, the single hinge operative to causethe card to transition from a flat unfolded configuration to afolded configuration by folding the first part over the secondpart about a single folding line. The method is furthercarried out by providing a force-exerting element on the card,wherein in the folded configuration the force-exerting elementapplies a repulsive force that urges the first part to moveapart from the second part, and forming an electrical contacton the first part of the card, wherein in the foldedconfiguration the electrical contact and a correspondingportion of the second part define a plug assembly forinsertion into an electrical receptacle to form an electricalconnection therewith. The thickness of the plug assembly isless than half a width dimension of the receptacle, whereinwhen the plug assembly is received by the receptacle, thefolding line is outside the receptacle, and the repulsiveforce causes the electrical contact on the first part of the card to engage an electrical contact of the receptacle.

Further embodiments of the invention are stated in the dependent claims.

Detailed exemplary embodiments and advantages of the card andthe manufacturing method according to the invention will nowbe described with reference to the appended drawings illustrating some preferred embodiments.

Brief description of the drawings Figs. la-f show different examples of cards according to the invention.

Figs. 2a-b show cross sectional views of the USB plug being inserted into the USB receptacle.

Figs. 3a-b show a creased hinge.

Figs. 4a-b show a locking mechanism.

Figs. 5a-c show cross sectional views of hinges.

Figs. 6a-b show a curved aperture and chamfered portion of a card, respectively.

Figs 7a-d show use of a protection mechanism Fig. 8 shows a foldable card with a display.

Figs 9a-b show manufacturing method steps.

Figs lOa-b show an injection moulded hinge.

Detailed description of preferred embodiments Figures 1a-le show different embodiments of a card 100according to the present invention. The card 100 has a firstpart 110 and a second part 120. These first part 110 andsecond part 120 are separated by a single hinge 130. The cardalso has electrical contact means 140. As can be seen infigures 1a-1e, the different embodiments of the card accordingto the invention are slightly different in their cut shape.However, they have a form being of essentially standard creditcard form, i.e. their periphery forms except for the piecesbeing cut away correspond to the form of a standard creditcard. The card 100 according to the invention is meant to beused as a USB plug by being folded together, such that the USB plug can be inserted into a USB receptacle.

Standard credit cards have a certain length and width, asdefined e.g. in the ID-1 standard. Standard credit cards alsohave a thickness being less than half of a width of thestandard USB receptacle. According to standard specifications,credit cards are specified to have a thickness beingessentially 0.76 mm, and to be essentially 85.6 mm long and53.98 mm wide. A standard USB receptacle has a gap beingapproximately 2.2 mm wide. Thus, the USB receptacle gap widthis more than twice as wide as the thickness of the standardcredit card. In this document, the USB receptacle width isdefined as the width in which an USB plug is to be fitted inorder to achieve electrical contact with the electricalcontact means of the USB receptacle, i.e. the width betweenthe electrical contact means of the USB receptacle and theopposite wall of the USB receptacle across the gap of the USB receptacle (indicated as dimension “G” in figure 2b).

As stated above, according to the invention, one single hinge130 is arranged between the first part 110 and the second part120. This single hinge 130 is foldable for providing 130single fold of the card 100. By this folding, the USB plug 150is formed by the first part 110 and the second part 120together.

The thickness of a standard credit card is less than half thewidth of the USB receptacle gap. Thus, in order to achieve asolid electrical contact between the electrical contact means140 of the card and the electrical contact means of the USB receptacle, some kind of contact providing arrangement has to be included in the card 100.

According to the present invention, a force providing arrangement is arranged for providing a repulsive force between the first part 110 and the second said part 120 whenthe card is folded. By this repulsive force, the electricalcontact means 140 of the card is forced against correspondingelectrical contact means of the USB receptacle when the USB plug 150 is inserted into the USB receptacle.

Thus, by this force providing means, the problem of achievingsolid electrical contact between the electrical contact means140 of the card and the electrical contact means of the USB receptacle, when the card is inserted into the USB receptacle, is solved.

Further, the card 100 according to the present invention onlyhas a single fold, which lowers the manufacturing costs incomparison to the multiple folds of the prior art cards. Also,this single fold is arranged on the card such that it will belocated outside the USB receptacle when the UBS plug 150 isinserted into the USB receptacle. Thus, the point of thesingle fold being closes to the electrical contact means 140of the card, i.e. the point of the single hinge 130 beingclosest to the electrical contact means 140 of the card, issituated at a distance from the electrical contact means 140,which ensures that no part of the fold is located within theUSB receptacle. For example, this distance can be essentiallyat least 4 mm long, and preferably at least 6 mm long.

The fact that the fold, according to the present invention, islocated outside the USB receptacle has a number of advantages.One such advantage is that the single hinge 130 being foldedis located at a distance away from the electrical contactmeans 140, which lowers the tension and forces being appliedon the electrical contact means 130 when the card 100 is beingfolded. This lowers the risk for the electrical contact means 140 to let loose of the card 100. Thus, the location of the 11 hinge 130 according to the present invention results in a more robust card 100.

Figures la-f show different forms of the card 100 according to different embodiments of the invention.

In figures la-c, and in figure lf, the electrical contactmeans 140 is arranged essentially in a corner of the card 100,and the single hinge 130 is arranged such that it at one endis directed towards to that corner. The single hinge 130 isarranged at an angle ß to the longer side edge of the card,i.e. at an angle ß to the longitudinal direction of the card.Thus, the single hinge 130 is here arranged essentiallydiagonally from a point the longer side edge of the card to that corner of the card.

In figure la, the electrical contact means 140 is located in adirection parallel with the shorter side of the card. Infigure 1c, the electrical contact means is arranged in adirection being essentially parallel with the single hinge,i.e. the electrical contact means is here directed towards the corner of the card.

In figures 1d-e, the electrical contact means 140 is locatedin a smart card chip position of the card 100. Thus, theelectrical contact means 140 is here located essentiallycentrally on the shorter side of the card, and at a distance from the shorter side edge.

In figure 1d, the single hinge 130 is arranged at an angle ßto the longer side edge of the card (at an angle B to thelongitudinal direction of the card), has one end of the hingeat a point on the edge of the longer side edge of the card,and has a direction essentially towards the electrical contact means 140. 12 In figure 1e, the electrical contact means 140 is arranged inthe smart card chip position, and the single hinge 130 isdirected parallel to the longer side of the card. Thus, the angle ß is here O° in this embodiment.

In figure lf, the card 100 is provided with protruding means133, being located essentially parallel to the single hinge 130, as will be described more in detail below.

Also, since the single hinge 130, and thereby also the singlefold, is located relatively far away from the electricalcontact means 130, and thus from the part of the card 100being inserted into the USB receptacle, a better contact is achieved by the card 100 of the present invention.

These advantages are illustrated in figures 2a and 2b. Infigure 2a, a cross section view from the side of a USBreceptacle 250 with an USB plug, including the first part 210of the card, the second part 220 of the card, and the electrical contact means 240, being inserted therein is shown.

In figure 2b, a cross section view from the back of a USBreceptacle 250 with an USB plug, including the first part 210of the card, the second part 220 of the card, and the electrical contact means 240, being inserted therein is shown.

As can be seen in figures 2a and 2b, the angle d between thefirst part 210 and the second part 220 of the USB plug is muchsmaller than the angle between corresponding parts of theprior art solutions. For example, in the prior art document US7,377,448, wherein one of the folds is arranged to be locatedwithin the USB receptacle, the angle between the folding partsis much larger than the angle d between the first part 210 and the second part 220 of the card. The smaller angle d, as being 13 achieved by the present invention, has an advantage in thatthe contact between the electrical contact means 140 and thecorresponding electrical contact means of the USB receptacleis much more solid, and is also much more evenly distributedover the whole electrical contact means 140, since the smallerangle d achieves a more even force distribution over theelectrical contact means 140. Also, the smaller angle dradically decreases the risk for the USB plug to loose itsgrip in the USB receptacle and to fall out.

Further, according to an embodiment of the invention, theabove mentioned force providing arrangement includes thesingle hinge 130. Thus, the single hinge 130 here creates the repulsive force when the card 100 is folded together.

Such a repulsive force creating hinge can be achieved in a number of ways. This will be described more in detail below.

According to an embodiment of the invention, the single hinge130 is an injection moulded hinge. By this injection moulding,the single hinge 130 can be arranged such that it provides therepulsive force between the first part 110 and the second part120 when the card is folded. Also, injection moulding is a very efficient manufacturing process for manufacturing cards according to the invention, which decreases the production costs.

According to en embodiment of the invention, the card 100 ismanufactured by the use of double injection moulding. Here,the single hinge 130 is a first element of the doubleinjection moulding. This first element is moulded at one timeinstant in the double injection moulding process, using afirst moulding material. The first part 110 and the second part 120 of the card 100 are then other elements of the double 14 injection moulding. These other elements are moulded atanother time instant than the first element, are of anothermoulding material, and are moulded such that the single hinge130 and the first part 110 and the second part 120 are fastened together.

When the single hinge 130 is a double injection mouldinghinge, the card 100 can be made to automatically, i.e. by itsown motion (by its own force), return to its non-foldedposition, i.e. to its flat position, due to stresses andstrains being created in the single hinge when the card isfolded. These forces are created by the single hinge beingarranged to be stronger on one side of the hinge than on theother side of the hinge. Hereby, the card returns to a non- folded position when it is pulled out of the USB receptacle.

The injection moulded hinge 130 can be made of any one of anumber of different materials. Such materials are PP(Polypropylene or Polypropene); PE (Polyethylene or polythene,IUPAC name: polyethene or poly(methylene)); POM(Polyoxymethylene); PC (Polycarbonates, IUPAC name:polyethyne); PA (Polyacetylene, IUPAC name: polyethyne); PET(Polyethylene terephthalate); an elastomer; a natural rubber; and a synthetic rubber.

Further, according to an embodiment of the present invention,the single hinge 130 is a creased hinge. When manufacturingthe creased hinge, material of the card is, by applyingpressure where the hinge is to be located, displaced, suchthat the creased hinge is achieved by deformation of the card100. This is a very low cost production process, which is applicable for cards being produced e.g. by lamination.

According to an embodiment of the invention, when the single hinge 130 of the card 100 is a creased hinge, the card 100 is arranged for counteracting the card deformation of the card 100 during the creasing.

This is illustrated in figures 3a and 3b, wherein the card100, before the creasing has been performed (shown in figure3a), has a form, which will counteract the deformation takingplace when creasing is performed. I.e., as can be seen infigure 3a, the second part 320 of the card 300 is slightlydisplaced in relation to the first part 310 of the card, suchthat the longer side of the card has a slightly unevenperipheral edge, such that the peripheral edge of the secondpart 320 has a slightly narrower width than the first part 310has. By the deformation resulting from an elongation obtainedby creasing the card, this slight displacement is re-displaced, such that the card becomes its normal form, as isshown in figure 3b. Thus, by the creasing deformation, thelonger side of the card has an even peripheral edge. Also,text being printed on the card has its normal shape when the card has been creased.

The creased hinge can be made of any one of a number ofmaterials, such as PP (Polypropylene or Polypropene); PET(Polyethylene terephthalate); PVC (Polyvinyl chloride, IUPACname: Poly(chloroethanediyl)); PE (Polyethylene or polythene,IUPAC name: polyethene or poly(methylene)); POM(Polyoxymethylene); ABS (Acrylonitrile butadiene styrene); PA(Polyacetylene, IUPAC name: polyethyne); and PC(Polycarbonates, IUPAC name: polyethyne).

Further, according to an embodiment of the present invention,the single hinge 130 is a milled hinge. This milled hinge hasa recess extending in a longitudinal direction of the milledhinge. Milled hinges are producible at very low cost, and can be useful e.g. for cards being produced by lamination. 16 Figures 5a-c show cross sectional views of different types ofhinges described above, each having a hinge width 501, and a hinge depth 502.

Figure 5a shows an injection moulded hinge in a non-folded,i.e. flat, position and in a folded position. Here, the body503 of the hinge is relatively thin. For example, the hingewidth 501 can be less than 1 mm (typically approximately 0.8mm), and the hinge depth 502 can be approximately 0.6 mm.

Figure 5b shows a creased hinge in a non-folded position andin a folded position. For example, the hinge width 501 can beless than 1 mm (typically approximately 0.8 mm), and the hingedepth 502 can be approximately 0.3 mm.

Figure 5c shows a milled hinge in a non-folded position,wherein the milled hinge can be made by essentially anymilling or cutting tool, such as a knife, a laser beam or thelike. As is shown in figure 5c, the milled hinge can be madeto have an essentially V-shaped cross section of the recess, or an essentially U-shaped cross section of the recess.

Further, as is shown from the back side of the card in figure1f, according to an embodiment of the invention, the forceproviding arrangement includes protruding means 133 arrangedon the card 100 on the back side of the card, i.e. on the sideof the card being opposite to the side where the smart cardchip and/or card number is provided. This protruding means 133is arranged on at least one of the first part 110 of the card100 and the second part 120 of the card 100. Also, it islocated such that it makes contact with the other one of thefirst part 110 and the second part 120 when said card isfolded. Thus, the at least one protruding means 133 is locatedon a side of at least one of the first and second parts, respectively, and arranged such that, when the card is folded, 17 it touches the other respective one of the first part 110 andthe second part 120. Thereby, the protruding means 133 createsthe repulsive force needed for ensuring the contact between the electrical contact means.

The protruding means 133 can have a large number of forms,such as one or more flanges, one or more bumps, one or morebulges, one or more swellings, or the like. The protruding 133means can be located essentially in any location of the firstpart 110 and/or the second part 120, as long as the sectionsof the first part 110 and the second part 120 being insertedinto the USB receptacle has a suitable angle d between them.Thus, the location of the protruding means 133 can be chosensuch that solid electrical contact is achieved. One suchfavorable location is adjacent to the electrical contact means140. One other such favorable location is shown in figure 1f,wherein the protruding means is located essentially parallelto the single hinge 130, on a distance from the single hinge130, such that the above mentioned suitable angle d betweenthe first part 110 and the second part 120 being is achieved.In figure 1f, the protruding means 133 is schematically shownas a line along which one or more flanges, bumps, bulges, swellings, or the like can be arranged.

As stated above, the single hinge 130 can extend in differentdirections across the card 100. According to an embodiment ofthe present invention, the single hinge 130 extends in a longitudinal direction of the card 100. Thus, the single hingeis here essentially parallel with the longer side edge of thecard. This location of the single hinge 130 is illustrated in figure 1e.

According to another embodiment of the invention, the single hinge 130 extends in a direction, which has an angle B to a 18 longitudinal direction of the card. Thus, the single hinge ishere arranged at an angle ß to the longer side edge of thecard. This location of the single hinge 130 is illustrated infigures 1a, 1b, 1c, ld. Specially, according to an embodiment,this angle ß is approximately 45°. Thus, according to thisembodiment, the single hinge is arranged essentiallydiagonally at least partially across the card. The singlehinge here extends diagonally from a point of the longer sideedge of the card in a direction essentially towards theelectrical contact means. As is shown in figures 1a-c, theelectrical contact means can be provided adjacent to, i.e. ina vicinity of, a corner of the card, towards which corner the single hinge is essentially directed.

To arrange the single hinge essentially diagonally, i.e. at anangle ß to the longitudinal direction of the card, has anadvantage in that, when the card is folded for insertion intoan USB receptacle, as is shown in figure 1b, the card onlytake up one USB port. Especially, when the electrical contactmeans 140 are arranged in a corner of the card, wherein thecorner essentially is in the direction of the single hinge, ascan be seen in figure 1a and 1b, the left hand side of thecard in figure 1b is essentially aligned with the USB plugside. Thus, another USB plug can easily be inserted in yetanother USB receptacle side by side with the USB receptacle inwhich the foldable card 100 is inserted. Also, when using adiagonal hinge, as shown in figure 1a-b, a large portion ofthe first part 110 is left unfolded, and can be provided with a chip, such as a smart card chip or the like.

This non-blocking feature of the USB plug is also achieved bythe card in figure 1e, wherein the single hinge 130 is located in a longitudinal direction of the card, relatively close to 19 the electrical contact means 140, but ending at a distancefrom the electrical contact means 140, i.e. the hinge 130being located outside the USB receptacle when being inserted into the USB receptacle.

According to another embodiment of the invention, the singlehinge 130 extends in a direction being essentially perpendicular to a longitudinal direction of the card.

As is shown in figures 4a-b, according to an embodiment of thepresent invention, the card 400 is provided with locking means401 arranged for keeping said card in a non-folded position,i.e. in a flat position. This locking means 401 can bearranged, for example, adjacent to the electrical contactmeans 430, in a location 403, wherein the locking means,typically being arranged by one or more protruding means, canreach from the first part 410 to the second part 420 of the card, or vice versa.

Also, the locking means 401 can be arranged in at a peripheralend 402 of the single hinge 430, i.e. where the single hinge430 meets the longer side edge of the card 400. Also, thelocking means can be arranged essentially anywhere along the single hinge 130, where a solid locking is achievable.

Figure 6a shows another embodiment of the present invention,in which a curved aperture 660 is arranged in the card 100 atone or more peripheral ends of the single hinge 630. I.e., apiece of material is removed from the card at its peripheraledge where the single hinge reaches the longer side edge ofthe card 600 such that the curved aperture is formed. Theaperture thus can have the form of half a hole or a bay.Typically, the curved aperture 660 is arranged where the single hinge 630 meets the longer side edge of the card 600.

This aperture 660 has an advantage in that it releasestensions and forces building up at the peripheral ends of the single hinge 630 during folding of the card.

Figure 6b shows another embodiment of the present invention,in which the one of the first part 610 and the second part 620to be inserted into the USB receptacle not being provided withthe electrical contact means is provided with a chamferedportion 680, i.e. a portion being corrugated, grooved,knurled, rifled or the like, such that the portion provides anincreased friction towards other materials. Thus, one of thefirst part 610 and the second part 620 is provided with achamfered portion, whereby when the USB plug is formed byfolding the card, the USB plug on one peripheral side has theelectrical contact means, and on the opposite peripheral side has the chamfered portion 680.

Thereby, when the USB plug has been inserted into the USBreceptacle, an increased friction between the USB plug and theUSB receptacle is achieved, thereby further decreasing therisk of that the USB plug would loose its grip within the USBreceptacle and fall out of the USB receptacle.

When the card is produced by the use of double injectionmoulding, the chamfered portion 680 can be formed by oneseparate material, such as rubber, during the double injectionmoulding. Thus, the card here includes chamfers, corrugations,grooves, knurls, rifles or the like, comprising this separate material, which can be rubber.

As is shown in figure 1e, the card 100 according to anembodiment of the invention, has a form such that a first end 170 of the card has a form being possible to releasably fasten 21 in a card holder 180. By this form of the card 100, it iseasily usable also as e.g. a company ID-card or the like, which can be releasable kept in the card holder.

Further, as is illustrated in figure le and figure 6,according to an embodiment of the present invention, the cardcomprises a seal 190, 690. The seal is arranged on the card100, 600 such that it has to be broken off to make use of saidcard 100, 600 possible. Thus, the seal 190, 690 can de used toensure that a user of the foldable card 100, 600 knows that heis the first one to use the card. E.g. the user thereby alsoknows that he is the first one to gain knowledge of theinformation stored in the card if the seal is unbroken, whichcan be very advantageous in some situations, e.g. for transfer of classified information.

Further, according to an embodiment of the invention, the cardis provided with protection means. This embodiment, and theuse of it, is disclosed in figures 7a-d. The card 700 herecomprises protection means 701, which is arranged to bedisplaceable between a first position shown in figure 7a, anda second position shown in figures 7b-d. In the firstposition, the protection means 701 covers the electricalcontact means 740. In the second position, the electricalcontact means 740 is exposed. In other words, in the firstposition, the card 700 is in a transport state, and in thesecond position, the card 700 is in a use state. Hereby, thecard can be safely transported, e.g. in a wallet, without anyrisk of degrading or destroying the electrical contact means 740.

In the second state, the protection means 701 also locks the card in a folded state, as is shown in figure 7d. When the 22 protection means 701 is again displaced to the first position,the locking effect of the protection means ceases, and the second part of the card being folded is released.

Further, according to an embodiment of the invention, the cardcomprises a display arranged for displaying information. Sucha card 800, and the layers of that card 800, are shown infigure 8. The card 800 has a display 801 being included in thecard 800. Also, the card 800 has a micro chip being locatedadjacent to the display 801, and being connected to thedisplay and to an external power supply. The card further hasa Printed Circuit Board (PCB) 803, corresponding to the abovementioned electrical contact means of the USB plug formed byfolding the card, and a PCB connection means 802 being connected to the display 801, the microchip, and the PCB 803.

The card according to this embodiment of the invention may beuseful for authentication purposes, one-time passwords, login purposes and the like.

The external power supply can be a power supply providingpower via the USB plug. Thus, the power can here be providedby e.g. a computer having the USB receptacle. The externalpower supply can also be a power supply providing power by utilizing induction.

Figure 8 also shows the different layers of the card 800. Thecard is formed of a bottom sheet 806, preferably beinginjection moulded, the display 801, the PCB connection means802, a top sheet 807 and the PCB 803 (the USB chip). The topsheet is provided with a window 804, such that the display isvisible 805 in the finally assembled card 800, after the lamination step 808. 23 Further, the foldable card according to the invention can alsobe provided with one or more of a magnetic strip, a smart cardship, and a Radio Frequency Identification (RFID) means. Thus,the card can also work as a normal credit card, a smart card,and/or a RFID device. The use of only one single hinge, inaccordance with the invention, makes it possible to have e.g.also the magnetic strip on the card, since in the first part110 of the card, as shown in figure 1a, the card does not haveto be folded along the longitudinal side of the card. Thus, amagnetic strip would not be folded here, and can thus bearranged on the card. Also, due to the form of the card of theinvention, having only one single hinge, there is plenty of room for the smart card chip and the RFID means.

Further, the foldable card according to en embodiment of theinvention has a contact segment, in which the USB chip and theelectrical contact means 140 are at least partly overlapping.Thus, the USB chip and the electrical contact means are herepositioned such that USB chip is slightly included in theelectrical contact means 140. Thereby, the printable area ofthe foldable card is increased, since the size of theessentially square cut-away (void) between the first andsecond parts of the card can be decreased. This essentiallysquared cut-away positioned between the first and second partsis shown e.g. in figures 1a, 1d, 1f, 3a, 3b, 4a, 6a, 6b, and9b.

To sum up the devices according to a couple of differentembodiments of the present invention, and to describe them inother words, the present invention according to an embodimentrelates to an electrical device for use with a receptaclehaving internal contacts adjacent to an internal gap. The electrical device comprises a card substrate having 24 rectilinear sides. First and second parts of the cardsubstrate are separated by a border obliquely orientedrelative to the rectilinear sides. For example, the border maybe diagonally oriented, i.e., directed toward two non-adjacentcorners of the card substrate. A resilient hinge is formedalong the border external to the electrical contacts. Thehinge is configured to bend so as to permit the second part ofthe card substrate to fold over the first part so that thefirst end of the first part and a corresponding second end ofthe second part are together insertable into the receptaclegap and arranged to exert an outward force within the gap thatholds the electrical contacts of the card 100 against the internal contacts of the receptacle.

Also, according to an embodiment of the invention, a foldablecard device 100 is presented, which comprises a first part anda second part hingeably connected to the first part by aresilient single hinge, wherein the single hinge is operativeto enable the card to transition from a flat unfoldedconfiguration to a folded configuration by folding the firstpart over the second part about a single folding line. Thesingle hinge is further operative to exert a repulsive force,which force in the folded configuration urges the first partto move apart from the second part. The foldable card device100 further comprises a first electrical contact on the firstpart of the card. In the folded configuration the firstelectrical contact and a corresponding portion of the secondpart define a plug assembly for insertion into an electricalreceptacle to form an electrical connection therewith. Whenthe plug assembly is received by the receptacle, the foldingline is located outside the receptacle, and the repulsiveforce causes the first electrical contact to engage a second electrical contact of the receptacle. lO Also, according to an embodiment of the invention, anelectrical device is presented, which is arranged for use witha receptacle having internal contacts adjacent to an internalgap. The electrical device comprises a card substrate havingrectilinear sides and comprising first and second parts beingseparated by a border that is obliquely oriented relative tothe rectilinear sides. The device further comprises electricalcontacts being located at a first end of the first part of thecard substrate and configured to mate with the internalcontacts of the receptacle. The electrical device furthercomprises a hinge, which is formed along the border and isconfigured to bend so as to permit the second part of the cardsubstrate to fold over the first part so that the first end ofthe first part and a corresponding second end of the secondpart are together insertable into the receptacle gap. Theelectrical device further comprises protrusions formed on atleast one of the first part and the second part, wherein in afolded configuration of the card substrate, the protrusionsthat are disposed on one of the first part and the second partcontact another of the first part and the second part andexert an outward force within the gap that holds theelectrical contacts against the internal contacts of the receptacle.

The above disclosed embodiments of the invention provide adurable, singly-hinged foldable card device configured with anelectrical connector for reliable conductive connection to areceptacle. The card device can be manufactured veryefficiently. The single hinge and electrical connectorappropriate only a small proportion of the card area, leavingample space for printing data and large images on the card.

Moreover, when inserted into one of a cluster of receptacles, 26 hinged arrangement prevents the card-device from obstructing neighboring receptacles.

Further, according to an aspect of the invention, amanufacturing method for manufacturing the card is presented.According to the method, the single hinge 130, 430, 630 isformed between the first part 110, 210, 310, 410 and thesecond part 120, 220, 320, 420 of the card 100, 300, 400, 600,700, 800. The single hinge 130, 430, 630 is foldable forproviding a single fold of the card 100, 300, 400, 600, 700,800, whereby an USB plug 150 is formed by first part 110, 210,310, 410 and the second part 120, 220, 320, 420 together. Thesingle fold is arranged to be located outside the USBreceptacle when the UBS plug 150 is inserted into the USB receptacle.

Also, according to the method of the invention, the card 100,300, 400, 600, 700, 800 is provided with a force providingarrangement, which causes a repulsive force between the firstpart 110, 210, 310, 410 and the second said part 120, 220,320, 420 when the card is folded. By this repulsive force, theelectrical contact means 140, 240, 440, 740 is arranged to beforced against corresponding electrical contact means of theUSB receptacle when the USB plug 150 is inserted into the USBreceptacle, even though the card is of standard credit cardsize having a thickness being less than half of width of thegap (opening) of the USB receptacle.

In other words, a method for manufacturing a foldable carddevice is presented, in which a card having a first part and asecond part is formed. Thereafter, a single hinge is formed inthe card to hingeably connect the first part of the card to the second part of the card. The single hinge is operative to 27 cause the card to transition from a flat unfoldedconfiguration to a folded configuration by folding the firstpart over the second part about a single folding line, whereinin the folded configuration the single hinge applies arepulsive force that urges the first part to move apart fromthe second part. Also, a first electrical contact is formed onthe first part of the card, wherein in the foldedconfiguration the first electrical contact and a correspondingportion of the second part define a plug assembly forinsertion into an electrical receptacle to form an electricalconnection therewith. When the plug assembly is received bythe receptacle, the folding line is located outside thereceptacle, and the repulsive force causes the firstelectrical contact to engage a second electrical contact of the receptacle.

According to an embodiment of the invention, the card 100,300, 400, 600, 700, 800 is injection moulded. According toanother embodiment, the card 100, 300, 400, 600, 700, 800 isdouble injection moulded, whereby the single hinge 130, 430,630 is first moulded by use of one material and then the firstpart said second parts are moulded by the use of anothermaterial. The materials used are as specified above formoulded hinges. One such advantageous material to be used for moulding the single hinge is an elastomer.

Further, according to an embodiment of the present invention,a double injection moulding method is used for manufacturingthe card. Figures 10a and 10b shows hinges manufactured bysuch double injection moulding. According to the method, thecard, i.e. the first and second parts of the card, is firstinjection moulded. Thereafter, the single hinge is injectionmoulded in the same moulding form as was used for injection moulding of the card. 28 The single hinge can be arranged to have the physicalproperties as shown in figures lOa and 10b, wherein the singlehinge 130 is formed such that it is strengthened on one firstside 131 of the hinge, thereby achieving that the card returnsto a non-folded position when it is released, e.g. pulled outof the USB receptacle. The hinge is also provided with atleast one flange 132 extending way from the portion of thehinge being folded, e.g. extending essentially perpendicularto the fold. By this one or more flange, a very solid bondingbetween the single hinge and the card is created, since thisone or more flanges 132 bond with one or more depressions,respectively, such as valleys or the like, of the first andsecond parts (110, 120) of the card, thereby increasing thebonding area between the hinge and the first and second part(110, 120) of the card, respectively. Each one of the one ormore flanges can have essentially any shape increasing this bonding area, such as a lip, a rib, a column, or the like.

Further, according to an embodiment of the invention, the cardis manufactured by milling the single hinge in the card. Thesteps of this manufacturing method are shown in figure 9a, and are described in the following.

In step 1 of the method, top and bottom layers/sheets areprinted. The two main layers are laminated together, possiblyalso with two protecting layers. The top layer is here of astiffer material to give the card rigidness, while the bottomlayer is of a softer material to make it possible to in use fold the card without signs of cracks in the material.

In step 2 of the method, the card is punched/stamped out of the laminated sheet. lO 29 In step 3 of the method, the shape of sections including theelectrical contact means are punched/stamped. The punch toolis here arranged to not go through the whole thickness of thecard, i.e. the punched segment is still attached to the card,possibly being perforated to form a seal. The use of thepunching tool is a very low cost production method, being well suited for mass production.

In step 4 of the method, a pocket is milled for the USB chipand/or the smart card chip. Also, the area between thesections including the electrical contact means is milledthrough the whole thickness of the card. Also, the line wherethe card is to be folded is milled, i.e. the single hinge iscreated. Here, only the top layer is removed by the milling, thereby creating the single hinge.

In step 5 of the method, the microchip and/or the USB chip isplaced and fastened in the milled pocket.

Further, according to an embodiment of the invention, the cardis manufactured by creasing the single hinge in the card,thereby creating a creased hinge. The steps of thismanufacturing method are shown in figure 9b, and are described in the following.

In step l of the method, the top and bottom layers/sheets areprinted. The sheets are laminated together, possibly also with two protecting layers.

In step 2 of the method, the card is punched/stamped out of the laminated sheet.

In step 3 of the method, the shape of the sections includingthe electrical contact means are punched/stamped. As discussed above, the punch tool can here be design to form a seal in the lO upper left corner, i.e. it can leave the rest of the punched- away card segment attached.

In step 4 of the method, a pocket is milled for the USB chipand/or the microchip. The chip is then placed in the pocket.

In step 5 of the method, a crease tool forms the single hinge to make the card foldable.

The card and the manufacturing methods according to theinvention may be modified by those skilled in the art, as compared to the exemplary embodiments described above.

As is obvious for a skilled person, a number of otherimplementations, modifications, variations and/or additionscan be made to the above described exemplary embodiments. Itis to be understood that the invention includes all such otherimplementations, modifications, variations and/or additions which fall within the scope of the claims.

Claims (1)

1. 31 Claims 1. A card (100) being foldable for forming an USB plug (150)being insertable into an USB receptacle, said card (100)comprising electrical contact means (140), and essentiallybeing of standard credit card dimensions, having a thicknessbeing less than half of a width of said USB receptacle,characterized by: - a single hinge (130) being arranged between a first part(110) and a second part (120) of said card, said single hinge (130) extending in a direction having an angle ß of approximately 45° to a longitudinal direction of said card, andwbeing-Mfoldable for providing a single fold of said card,whereby an USB plug (150) is formed by said first part (110) and said second part (120) together, and said single fold is arranged to be located outside said USB receptacle when saidUBS plug (150) is inserted into said USB receptacle;-afid - a force providing arrangement including said single hinge (130), said force providing arrangement being arranged for providing a repulsive force between said first part (110) andsaid second part (120) when said card is folded, such thatsaid electrical contact means (140) is arranged to be forcedagainst corresponding electrical contact means of said USBreceptacle when said USB plug (150) is inserted into said USB receptacle; and - said contact means being arranged essentially in a corner of said card (100) and having an angle of approximately 45° to said single hinge (130). b.)Mr09HO..:ICD(Douof..Jo*JšQs0F.)wPJšFJrHs 32 | 32. The card (100) as claimed in claim 1%, wherein said single hinge (130) is an injection moulded hinge. I âë. The card (100) as claimed in claim gå, wherein said single hinge (130) is a first element of a double injection moulding, and said first (110) of said (100) and second part (120) card are other elements of said double injection moulding. gå. The card (100) as claimed in anyone of claims 3%-Ã4,wherein said injection moulded hinge is made of any of thematerials in the group of: - PP (Polypropylene or Polypropene); - PE (Polyethylene or polythene); - POM (Polyoxymethylene); - PC (Polycarbonates); - PA (Polyacetylene); - PET (Polyethylene terephthalate);- an elastomer; - a natural rubber; and - a synthetic rubber. I âê. The card (100) as claimed in claim 1%, wherein said single hinge (130) is a creased hinge. i §4. The card (100) as claimed in claim âé, wherein said card(100) is arranged for counteracting a card deformation of saidcard, said deformation resulting from an elongation obtained by creasing said card. 18. The card (100) as claimed in anyone of claims âê-§4,wherein said creased hinge is made of any of the materials inthe group of: - PP (Polypropylene or Polypropene); - PET (Polyethylene terephthalate); lO 33 - PVC (Polyvinyl chloride); - PE (Polyethylene or polythene); - POM (PolyoXymethylene); - ABS (Acrylonitrile butadiene styrene);- PA (Polyacetylene); and - PC (Polycarbonates). §9. The card (100) as claimed in claim 1%, wherein saidsingle hinge (130) is a milled hinge having a recess extending in a longitudinal direction of said milled hinge. 210. The card (100) as claimed in any one of claims 1-§9,wherein said force providing arrangement includes protruding means (133) arranged on said card. 1011. The card (100) as claimed in claim 210, wherein saidprotruding means (133) is arranged on at least one of saidfirst part (110) and said second part (120) of said card,respectively, such that said protruding means (133) makescontact with the other one of said first part (110) and saidsecond part (120) of said card, respectively, when said card is folded, thereby providing said repulsive force. 1fi W n~vA 11nn\ am fiïaåm A än awflfin C ~1~~~fi 1 11 .LQ- .Lil-kl QEJHLKJ. \.L\J\J/ RÅJD \/.L.kA.LllI-L»\-A. .LLL LÅ..L¿I\JL¿\J \/A_ \.».L{J.J.llh_7 J. LJ.,H v ån ~~«A ~~fi~1 1fi~ {11n\ v+ “Am sn a 1 fi~~+“A4w«1VVLJ. .L\'.L_L.L nJQ/L.LX/L \.J..LJ.J.5.L.\.. .LLLJNLÜ \J..JU] çßbkflxLl-LJ .LULJ CA. J. .LLÜ..L\f\4LkÅ..LJ.LL/L.L 13 mh ~~vA /1nn\ am mífiäm A 4” an" W AF nïfiåmfi 1 11J-Jq .Lil-Q \4CÅJ-\.Å. \J.\J\l/ CAC .LLL.Llll\«\/L .LAL šÅJ-.LIMJJ-J. \.J.L \.«.LLÅ..LUHÛ .L .L.L, vß “Am âfi Q Aâv næå w k~fl4w~LJXX, .LJAAC .LLL LL \J..LJ.. \/\f.L\J.L). JULI/LV .Llig Äv nbånw F mflåfl mfivfl4.¿.\d\.p.x.wx1 V4. Quiu uLuL. SI)ESQ)IISLL)§._.|CtoÜCS)|,...JCïS(Q|....IH:IQ.. (Q...IESSI)|,.._|Q.. (2 än -nf-.ww- v-:M-fl- 'in A1:V .LuJ KAbJkJLMJJX~LHKJL .L 'IJ 1116. The card (100) as claimed in anyone of claims 1-1015,wherein said standard credit card dimensions correspond to ID-1 standard dimensions, wherein said card has a thickness being essentially 0.76 mm. 131%. The card (100) as claimed in anyone of claims 1-1116,wherein said card comprises locking means (401) arranged for keeping said card in a flat position. 1§&8. The card (100) as claimed in anyone of claims 1-1214,wherein a curved aperture (660) is arranged in said card at least at one peripheral end of said single hinge (130, 630). 1í19. The card (100) as claimed in anyone of claims 1-1§18,wherein one of said first part (110) and said second part(120) of said card (100) is provided with a chamfered portion(680), said chamfered portion (680) being arranged forproviding increased friction between said USB plug (150) andsaid USB receptacle when said USB plug is inserted into said USB receptacle. lâêê. The card (100) as claimed in anyone of claims 1-lâlä,wherein a first end (170) of said card has a form being possible to releasably fasten in a card holder (180). 162%. The card (100) as claimed in anyone of claims 1-lâëë, wherein said card comprises a seal (190), said seal (190) being arranged such that said seal (190) has to be broken off to make use of said card possible. 1122. The card (100) as claimed in anyone of claims l-1§21,wherein said card comprises protection means (701) beingarranged to be displaceable between a first position and asecond position, said protection means being arranged forcovering said electrical contact means (140, 740) in saidfirst position and for exposing said electrical contact means in said second position. 1§22. The card (100) as claimed in claim 1122, wherein saidprotection means (701) in said second position is arranged to lock the card in a folded state. 1224. The card (100) as claimed in anyone of claims 1-1§22,wherein said card comprises a display (801) arranged for displaying information. 2025. The card (100) as claimed in claim 1224, wherein said display is connectable to external power supply means. 2126. The card (100) as claimed in claim 2025, wherein saidexternal power supply is anyone in the group:- a power supply providing power via said USB plug; and - a power supply providing power by utilizing induction. 1222. The card (100) as claimed in anyone of claims 1224-1125,wherein said card comprises a micro chip, said micro chipbeing located adjacent to said display (801), and is connected to said display and to said external power supply. lO 36 ââåâ. The card (100) as claimed in anyone of claims 1-§§%¥,wherein said card further comprises one or more of thefeatures in the group: - a magnetic strip; - a smart card ship; and - a Radio Frequency Identification (RFID) means. 24 29. Method for manufacturing a card (100) being foldable forforming an USB plug (150) being insertable into an USBreceptacle, said card (100) comprising electrical contactmeans (140), and being essentially of standard credit carddimensions, having a thickness being less than half a width ofsaid USB receptacle, characterized in: - forming a single hinge (130) between a first part (110) anda second part (120) of said card, said single hinge (130) extending in a direction having an angle ß of approximately 45° to a longitudinal direction of said card, and being foldable for providing a single fold of said card, whereby anUSB plug (150) is formed by said first part (110) and saidsecond part (120) together, and said single fold is arrangedto be located outside said USB receptacle when said UBS plug(150) is inserted into said USB receptacle;~anå - providing said card with a force providing arrangement including said single hinge (130), T~said force providing arrangement being arranged for providing a repulsive forcebetween said first part (110) and said second part (120) whensaid card is folded, such that said electrical contact means(140) is arranged to be forced against correspondingelectrical contact means of said USB receptacle when said USB plug (150) is inserted into said USB receptacle; and 37 - said contact means being arranged essentially in a corner of said card (100) and being arranged to have an angle of approximately 45” to said single hinge (130). åêââ. Method as claimed in claim %9âg, wherein said card (100) is injection moulded. èægâ. Method as claimed in claim åêgg, wherein said card (100)is double injection moulded, wherein said single hinge (130)is first moulded and then said first part (110) and said second part (120) are moulded. %227. Method as claimed in claim êæåg, wherein said single hinge (130) is moulded with an elastomer. 3êg§¿ Method as claimed in claim êâgê, wherein said single hinge (130) is milled in said card (100). %4ââ. Method as claimed in claim êêâg, wherein said single hinge (130) is creased in said card (100).