WO2003105065A1 - Wallet card with built-in light - Google Patents

Wallet card with built-in light Download PDF

Info

Publication number
WO2003105065A1
WO2003105065A1 PCT/US2003/018736 US0318736W WO03105065A1 WO 2003105065 A1 WO2003105065 A1 WO 2003105065A1 US 0318736 W US0318736 W US 0318736W WO 03105065 A1 WO03105065 A1 WO 03105065A1
Authority
WO
WIPO (PCT)
Prior art keywords
core member
card
cavity
source
wallet card
Prior art date
Application number
PCT/US2003/018736
Other languages
French (fr)
Inventor
Alan Finkelstein
Original Assignee
Lenscard U.S., Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lenscard U.S., Llc filed Critical Lenscard U.S., Llc
Priority to CA002489152A priority Critical patent/CA2489152A1/en
Priority to AU2003248689A priority patent/AU2003248689A1/en
Priority to BRPI0312135A priority patent/BRPI0312135A2/en
Priority to EP03757501A priority patent/EP1514220A4/en
Priority to JP2004512062A priority patent/JP2005530228A/en
Priority to MXPA04012575A priority patent/MXPA04012575A/en
Publication of WO2003105065A1 publication Critical patent/WO2003105065A1/en
Priority to IL165668A priority patent/IL165668A/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
    • B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
    • B42D25/40—Manufacture
    • B42D25/45—Associating two or more layers
    • B42D25/465—Associating two or more layers using chemicals or adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
    • B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
    • B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
    • B42D25/20—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof characterised by a particular use or purpose
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B25/00—Eyepieces; Magnifying glasses
    • G02B25/002—Magnifying glasses
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/08—Simple or compound lenses with non-spherical faces with discontinuous faces, e.g. Fresnel lens
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
    • G06K19/04—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the shape
    • G06K19/041—Constructional details
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
    • G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
    • G06K19/06187—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code with magnetically detectable marking
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
    • G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
    • G06K19/067—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components
    • G06K19/07—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components with integrated circuit chips
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
    • G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
    • G06K19/067—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components
    • G06K19/07—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components with integrated circuit chips
    • G06K19/077—Constructional details, e.g. mounting of circuits in the carrier
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
    • G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
    • G06K19/067—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components
    • G06K19/07—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components with integrated circuit chips
    • G06K19/077—Constructional details, e.g. mounting of circuits in the carrier
    • G06K19/07745—Mounting details of integrated circuit chips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Definitions

  • the present invention relates to wallet cards and is specifically directed to a wallet card, such as a credit card, having a built-in light.
  • sources of illumination e.g. flashlights
  • sources of illumination e.g. flashlights
  • U.S. Patent No. 5,927,846 Such a light is shown, for example, in U.S. Patent No. 5,927,846.
  • these prior art lights are significantly thicker than an ordinary credit card and, therefore, do not meet ISO standards for such cards. Accordingly, prior art card shaped lights are incapable of functioning as financial transaction cards.
  • the present invention provides a financial transaction card that has a thin, flat, substantially rigid substrate and a source of illumination disposed within the substrate.
  • a source of electrical current is coupled to the source of illumination and a switch is provided to selectively close an electrical circuit between the source of electrical current and the source of illumination.
  • embossed alphanumeric indicia are included on the substrate.
  • Such a card may be made by printing first transaction card graphics on a first surface of a first core member and laminating a first overlay to the first surface of the first core member. A cavity is routed in a second surface of the first core member and a light is installed in the cavity. The cavity is then filled. Second transaction card graphics are printed on a first surface of a second core member and a second overlay is laminated thereto. The two core members are then joined by securing the second surface of the first core member to a second surface of the second core member.
  • FIGURE 1 shows the top side of a wallet card incorporating a magnifying lens
  • FIGURE 2 shows the bottom side of the wallet card of FIGURE 1 ;
  • FIGURE 3 is a plan view of a wallet card incorporating a light in accordance with the subject invention.
  • FIGURES 4A-4E illustrate a method of constructing a wallet card incorporating a light.
  • a typical credit card 10 is shown in Figure 1.
  • the size and general layout of card 10 have become standardized and similar cards are widely used for a variety of transactions and other purposes.
  • similar cards are used as debit cards, ATM access cards, gift cards, driver's licenses, identification cards, library cards, etc.
  • Such cards are typically carried in a wallet and are generally referred to herein as "wallet cards”.
  • Card 10 includes, as is common, embossed lettering at 12, which is machine readable for permitting the credit card to be imprinted at a point-of-sale transaction.
  • embossed lettering at 12 which is machine readable for permitting the credit card to be imprinted at a point-of-sale transaction.
  • most credit cards now contain a strip 14 for carrying machine readable information, for example a magnetic strip material which includes magnetically encoded information readable by computer terminals utilized in many point-of-sale terminals.
  • a signature strip 16 which is on the back of the card and which typically is adapted for receiving a signature to be manually applied by the user of the card.
  • the card may further include one- or multi-dimensional bar codes as well as smart card contact, contactless or combi-card electronic information storage.
  • the magnetic strip 14 and embossed lettering 12, along with the signature strip 16, identify a data zone on the card.
  • this data zone is generally controlled by ISO standards in an effort to standardize the cards so that various cards issued by a multiplicity of institutions may be used on standardized terminals the point-of-sale.
  • the placement of the magnetic strip 14 relative to the top edge 18 of the card is standardized, as is the width of the strip 14 in order to permit ready readability of the magnetically coded information by any typical point-of-sale magnetic reader.
  • the font, size and position of the embossed lettering 12 is controlled to assure machine readability of the information imprinted from the card when a point-of-sale transaction is made on a typical credit card imprinter. Only the position of the signature strip 16 can be altered without interfering with the machine readability of the card.
  • identifying indicia such as logotypes and the like as indicated at 20 for identifying the issuing institution.
  • An increasing number of cards also include a hologram panel 22 which includes issuing institution indicia.
  • the hologram panel 22 is generally located in or near the portion of the data zone including the embossed lettering 12.
  • a magnifying lens 24 is positioned such that it is in noninterfering relationship with the magnetic strip 14 and the embossed lettering 12.
  • the magnifying lens 24 is rectangular and is mounted parallel to the magnetic strip 14 in the space between the magnetic strip and the embossed lettering.
  • This space is generally sufficient in size to accommodate the lens 24 since it is required that the embossed lettering 12 be spaced sufficiently from the magnetic strip 14 to assure that the embossing of the card does not in any way alter the functionality of the magnetic strip.
  • a fresnel-type contour lens has been found to be particularly useful for this type of application. Such a lens is formed with concentric fresnel contour lines 36.
  • Figure 3 illustrates a wallet card 400 having a light 410 disposed on the bottom or reverse side 402 of a wallet card. This is particularly useful for assisting the user in examining magnified objects in a darkened environment.
  • card 400 may incorporate a lens 404 formed by the methods described in the referenced patents.
  • a magnetic stripe 406 and a signature panel 408 are provided as is customary.
  • Light 410 is preferably a light-emitting diode (LED), although any other suitable source of illumination may be utilized, such as a conventional incandescent bulb, electroluminescent panel or the like. Although only a single light 410 is illustrated, a plurality of lights may be installed, if desired.
  • LED light-emitting diode
  • Light 410 is powered by one or more batteries 414 disposed within card 400.
  • Switch 412 is placed at a convenient location on card 400.
  • Switch 412 is preferably a pressure sensitive switch that may be activated by finger pressure when card 400 is held between the thumb and index finger.
  • a method of manufacturing card 400 is illustrated in Figures 4A-4E. This method utilizes a split core construction to which front and rear overlays are laminated.
  • a first core member 420 has a thickness of approximately 24.4 mils.
  • the surface of core member 420 is printed with graphics appropriate for the particular card application.
  • the printed surface of core member 420 is then laminated with overlay 422, which has a thickness of approximately 1.6 mils.
  • the lamination process employs a pressure of about 400 psi and a temperature of about 100° C.
  • a cavity 424 is milled or routed into core member
  • the interconnection circuitry may be formed within cavity 424 by a printing process with conductive ink or by deposition of metallic circuit traces. Alternatively, the entire floor of cavity 424 may be metallized and circuit traces nay then be formed using a conventional photoetching process. Once the interconnection circuitry has been formed, the battery 414, LED 410 and switch 412 are inserted in respective areas of the cavity and electrically bonded to the interconnection circuitry using conventional bonding techniques. In another alternative, the components may be first connected electrically and mounted as a unit on a suitable carrier prior to being inserted into cavity 424.
  • the cavity 424 is filled with an ultraviolet
  • (UN) curable resin or a similar potting compound Once cured, the exposed compound 432 is milled or shaved flush with the surface of core member 420. This may be accomplished using a diamond impregnated fly cutter.
  • a second core member 434 is printed with appropriate graphics and laminated with overlay 436. Core member 434 has a thickness of approximately 5 mils, which is about the minimum for use with existing printing and laminating processes.
  • core members 420 and 434 are joined together as shown in Figure 4E.
  • a hot lamination process may be used; however, the electronic components, particularly battery 426, may suffer adversely in such a process.
  • core members 420 and 434 may be joined with a cold lamination process or may be glued together with a suitable adhesive. Acceptable adhesives are available that can join the core members at a temperature of only about 100° F, which is low enough to avoid damage to the electronic components.
  • the finished card has a thickness of approximately 32.6 mils, close to the nominal 32 mil thickness established by ISO standards and well within the allowable tolerance.
  • Figures 4A-4E illustrate the manufacturer of a single card, it will be understood that a plurality of cards may be processed simultaneously in sheets and that the sheets may then be cut into individual cards after the process is complete. Also, while cavity 424 is shown as being formed in core member 420, cooperating cavities may be formed in the two core members, in which case they may be equal, or nearly so, in thickness.
  • the completed card may include an integral magnifying lens, if desired.
  • core members 420 and 434 are preferably formed of a clear plastic material as described in the referenced patents.
  • the graphic design imprinted on the surfaces of the core members will, of course, leave a transparent window where the lens is to be located.
  • the lens may be formed by hot stamping fresnel contours as described in the referenced patents. Further processing of the card, such as embossing, the addition of holograms, magnetic stripes, etc. is accomplished in the same manner as for the previously patented embodiments. As mentioned above, appropriate care is taken to locate electronic components 430 in areas of the card that will not be subject to embossing.
  • a collimating lens 434 allows formation of a collimating lens for LED 410.
  • An LED typically disperses light over a wide angle.
  • a collimating lens concentrates the light within a narrower angle so that card 400 is a more effective source of illumination.
  • a collimating lens may be formed in the same manner as a magnifying lens. It will be understood, however, that incorporation of a collimating lens for LED 410 does not require that a magnifying lens also be included in card 400.
  • An alternative method of manufacturing card 400 is basically similar to the previously described method; however, the split core members are fabricated using an extrusion process. A first core member is extruded with a cavity in place. This core member is printed and laminated as in the previously described process. Furthermore, the electronic components are installed and potted in the same manner as previously described. A second core member is also extruded and is then laminated to the completed first core member.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Manufacturing & Machinery (AREA)
  • Credit Cards Or The Like (AREA)
  • Printing Methods (AREA)

Abstract

A wallet card (400), such as a financial transaction card, has a substantially non-foldable semi-rigid base. Optionally, the semi-rigid base may include a magnifying lens (404). One or more lights (410) are disposed in the card base to provide illumination.

Description

WALLET CARD WITH BUILT-IN LIGHT
BACKGROUND OF THE INVENTION
1. RELATED APPLICATIONS
[0001] This is a continuation-in-part of co-pending U.S. Patent Application Serial
No. 09/767,317 filed January 22, 2001, which is a continuation-in-part of U.S. Patent Application Serial No. 09/066,799 filed April 24, 1998, now U.S. Patent No. 6,176,430, which is a continuation-in-part of U.S. Patent Application Serial No. 08/758,640 filed November 27, 1996, now U.S. Patent No. 5,856,661, which is a continuation-in-part of U.S. Patent Application Serial No. 08/582,601 filed January 3, 1996, now U.S. Patent No. 5,608,203, which is a continuation of U.S. Patent Application Serial No. 08/250,801 filed May 27, 1994, abandoned, which is a continuation-in-part of U.S. Patent Application Serial No. 08/197,218, filed February 16, 1994, now U.S. Patent No. 5,434,405 which is a continuation-in-part of U.S. Patent Application Serial No. 07/834,490, filed February 12, 1992, now U.S. Patent No. 5,412,199.
2. FIELD OF THE INVENTION
[0002] The present invention relates to wallet cards and is specifically directed to a wallet card, such as a credit card, having a built-in light.
3. BACKGROUND
[0003] The previously issued co-owned patents, namely, U.S. Patent Nos. 5,412,199;
5,434,405; 5,608,203; 5,856,661; and 6,176,430 disclose wallet cards with integral magnifying lenses and methods for maldng such cards. The disclosures of these patents are incorporated herein by reference. Such wallet cards are convenient for magnifying and reading printed information, such as sales receipts and the hke. Frequently, the user of such a card will desire to read information in a low light situation. To facilitate this, it is desirable to have a source of illumination in proximity to the magnifying lens. Even without a magnifying lens, there are many situations in which it would be desirable to have a wallet card that incorporates a source of illumination.
[0004] Heretofore, sources of illumination, e.g. flashlights, have been proposed with the same general shape as a credit card or a similar wallet card. Such a light is shown, for example, in U.S. Patent No. 5,927,846. However, these prior art lights are significantly thicker than an ordinary credit card and, therefore, do not meet ISO standards for such cards. Accordingly, prior art card shaped lights are incapable of functioning as financial transaction cards.
SUMMARY OF THE INVENTION
[0005] The present invention provides a financial transaction card that has a thin, flat, substantially rigid substrate and a source of illumination disposed within the substrate. A source of electrical current is coupled to the source of illumination and a switch is provided to selectively close an electrical circuit between the source of electrical current and the source of illumination. As is customary for financial transaction cards, embossed alphanumeric indicia are included on the substrate.
[0006] Such a card may be made by printing first transaction card graphics on a first surface of a first core member and laminating a first overlay to the first surface of the first core member. A cavity is routed in a second surface of the first core member and a light is installed in the cavity. The cavity is then filled. Second transaction card graphics are printed on a first surface of a second core member and a second overlay is laminated thereto. The two core members are then joined by securing the second surface of the first core member to a second surface of the second core member. BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention may be more readily understood by referring to the accompanying drawings in which
[0008] FIGURE 1 shows the top side of a wallet card incorporating a magnifying lens;
[0009] FIGURE 2 shows the bottom side of the wallet card of FIGURE 1 ;
[0010] FIGURE 3 is a plan view of a wallet card incorporating a light in accordance with the subject invention.
[0011] FIGURES 4A-4E illustrate a method of constructing a wallet card incorporating a light.
[0012] Like elements are numbered alike throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0014] A typical credit card 10 is shown in Figure 1. The size and general layout of card 10 have become standardized and similar cards are widely used for a variety of transactions and other purposes. Apart from credit cards, similar cards are used as debit cards, ATM access cards, gift cards, driver's licenses, identification cards, library cards, etc. Such cards are typically carried in a wallet and are generally referred to herein as "wallet cards".
[0015] Card 10 includes, as is common, embossed lettering at 12, which is machine readable for permitting the credit card to be imprinted at a point-of-sale transaction. As is shown in Figure 2, most credit cards now contain a strip 14 for carrying machine readable information, for example a magnetic strip material which includes magnetically encoded information readable by computer terminals utilized in many point-of-sale terminals. Also included is a signature strip 16 which is on the back of the card and which typically is adapted for receiving a signature to be manually applied by the user of the card. The card may further include one- or multi-dimensional bar codes as well as smart card contact, contactless or combi-card electronic information storage.
[0016] The magnetic strip 14 and embossed lettering 12, along with the signature strip 16, identify a data zone on the card. For financial transaction cards, this data zone is generally controlled by ISO standards in an effort to standardize the cards so that various cards issued by a multiplicity of institutions may be used on standardized terminals the point-of-sale. For example, the placement of the magnetic strip 14 relative to the top edge 18 of the card is standardized, as is the width of the strip 14 in order to permit ready readability of the magnetically coded information by any typical point-of-sale magnetic reader. Likewise, the font, size and position of the embossed lettering 12 is controlled to assure machine readability of the information imprinted from the card when a point-of-sale transaction is made on a typical credit card imprinter. Only the position of the signature strip 16 can be altered without interfering with the machine readability of the card.
[0017] Today, many cards also include identifying indicia such as logotypes and the like as indicated at 20 for identifying the issuing institution. An increasing number of cards also include a hologram panel 22 which includes issuing institution indicia. The hologram panel 22 is generally located in or near the portion of the data zone including the embossed lettering 12. In the card shown in Figs. 1 and 2, a magnifying lens 24 is positioned such that it is in noninterfering relationship with the magnetic strip 14 and the embossed lettering 12. The magnifying lens 24 is rectangular and is mounted parallel to the magnetic strip 14 in the space between the magnetic strip and the embossed lettering. This space is generally sufficient in size to accommodate the lens 24 since it is required that the embossed lettering 12 be spaced sufficiently from the magnetic strip 14 to assure that the embossing of the card does not in any way alter the functionality of the magnetic strip. A fresnel-type contour lens has been found to be particularly useful for this type of application. Such a lens is formed with concentric fresnel contour lines 36.
[0018] Figure 3 illustrates a wallet card 400 having a light 410 disposed on the bottom or reverse side 402 of a wallet card. This is particularly useful for assisting the user in examining magnified objects in a darkened environment. Optionally, card 400 may incorporate a lens 404 formed by the methods described in the referenced patents. A magnetic stripe 406 and a signature panel 408 are provided as is customary. Light 410 is preferably a light-emitting diode (LED), although any other suitable source of illumination may be utilized, such as a conventional incandescent bulb, electroluminescent panel or the like. Although only a single light 410 is illustrated, a plurality of lights may be installed, if desired.
[0019] Light 410 is powered by one or more batteries 414 disposed within card 400.
Conventional wafer cell batteries may be used or a flat laminated battery may be constructed integrally with the wallet card. Ultra-thin battery construction is described, for example, in U.S. Patent Nos. 5,888,672 and 6,045,942.
[0020] To control operation of light 410, a switch, such as switch 412, is placed at a convenient location on card 400. Switch 412 is preferably a pressure sensitive switch that may be activated by finger pressure when card 400 is held between the thumb and index finger.
[0021] A method of manufacturing card 400 is illustrated in Figures 4A-4E. This method utilizes a split core construction to which front and rear overlays are laminated. A first core member 420 has a thickness of approximately 24.4 mils. The surface of core member 420 is printed with graphics appropriate for the particular card application. The printed surface of core member 420 is then laminated with overlay 422, which has a thickness of approximately 1.6 mils. The lamination process employs a pressure of about 400 psi and a temperature of about 100° C.
[0022] Referring next to Figure 4B, a cavity 424 is milled or routed into core member
420 to accept the electronic components denoted generally by reference numeral 430. These components include battery 414, at least one light-emitting diode (LED) 410, switch 412 and interconnection circuitry 429. The interconnection circuitry may be formed within cavity 424 by a printing process with conductive ink or by deposition of metallic circuit traces. Alternatively, the entire floor of cavity 424 may be metallized and circuit traces nay then be formed using a conventional photoetching process. Once the interconnection circuitry has been formed, the battery 414, LED 410 and switch 412 are inserted in respective areas of the cavity and electrically bonded to the interconnection circuitry using conventional bonding techniques. In another alternative, the components may be first connected electrically and mounted as a unit on a suitable carrier prior to being inserted into cavity 424.
[0023] With reference now to Figure 4C, the cavity 424 is filled with an ultraviolet
(UN) curable resin or a similar potting compound. Once cured, the exposed compound 432 is milled or shaved flush with the surface of core member 420. This may be accomplished using a diamond impregnated fly cutter. [0024] Turning next to Figure 4D, a second core member 434 is printed with appropriate graphics and laminated with overlay 436. Core member 434 has a thickness of approximately 5 mils, which is about the minimum for use with existing printing and laminating processes.
[0025] The core members 420 and 434 are joined together as shown in Figure 4E. A hot lamination process may be used; however, the electronic components, particularly battery 426, may suffer adversely in such a process. In this case, core members 420 and 434 may be joined with a cold lamination process or may be glued together with a suitable adhesive. Acceptable adhesives are available that can join the core members at a temperature of only about 100° F, which is low enough to avoid damage to the electronic components. The finished card has a thickness of approximately 32.6 mils, close to the nominal 32 mil thickness established by ISO standards and well within the allowable tolerance.
[0026] Although Figures 4A-4E illustrate the manufacturer of a single card, it will be understood that a plurality of cards may be processed simultaneously in sheets and that the sheets may then be cut into individual cards after the process is complete. Also, while cavity 424 is shown as being formed in core member 420, cooperating cavities may be formed in the two core members, in which case they may be equal, or nearly so, in thickness.
[0027] As mentioned above, the completed card may include an integral magnifying lens, if desired. If so, core members 420 and 434 are preferably formed of a clear plastic material as described in the referenced patents. The graphic design imprinted on the surfaces of the core members will, of course, leave a transparent window where the lens is to be located. The lens may be formed by hot stamping fresnel contours as described in the referenced patents. Further processing of the card, such as embossing, the addition of holograms, magnetic stripes, etc. is accomplished in the same manner as for the previously patented embodiments. As mentioned above, appropriate care is taken to locate electronic components 430 in areas of the card that will not be subject to embossing.
[0028] The use of a clear plastic material for core member 420 and/or core member
434 allows formation of a collimating lens for LED 410. An LED typically disperses light over a wide angle. A collimating lens concentrates the light within a narrower angle so that card 400 is a more effective source of illumination. A collimating lens may be formed in the same manner as a magnifying lens. It will be understood, however, that incorporation of a collimating lens for LED 410 does not require that a magnifying lens also be included in card 400.
[0029] An alternative method of manufacturing card 400 is basically similar to the previously described method; however, the split core members are fabricated using an extrusion process. A first core member is extruded with a cavity in place. This core member is printed and laminated as in the previously described process. Furthermore, the electronic components are installed and potted in the same manner as previously described. A second core member is also extruded and is then laminated to the completed first core member.
[0030] It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.

Claims

CLAIMSWHAT IS CLAIMED IS:
1. A wallet card comprising: a thin, flat, substantially rigid substrate; a source of illumination disposed within the substrate; a source of electrical current coupled to the source of illumination; a switch for selectively closing an electrical circuit between the source of electrical current and the source of illumination; and embossed alphanumeric indicia.
2. The wallet card of claim 1 wherein the source of illumination comprises a light emitting diode.
3. The wallet card of claim 1 wherein the switch comprises a pressure-sensitive switch disposed on the substrate.
4. The wallet card of claim 1 further comprising a magnifying lens disposed within the substrate adjacent to the source of illumination.
5. The wallet card of claim 4 further comprising a strip affixed on said substrate for carrying machine readable information.
6. The wallet card of claim 1 wherein the wallet card is a financial transaction card.
7. The wallet card of claim 6 wherein the embossed alphanumeric indicia comprises a financial transaction account number.
8. The wallet card of claim 1 further comprising a colhmating lens disposed within the substrate for collimating light emitted by the source of illumination.
9. A method of making a wallet card containing a light comprising: printing first transaction card graphics on a first surface of a first core member; laminating a first overlay to the first surface of the first core member; routing a cavity in a second surface of the first core member; installing a light in the cavity; filling the cavity; printing second transaction card graphics on a first surface of a second core member; laminating a second overlay to the first surface of the second core member; securing the second surface of the first core member to a second surface of the second core member.
10. The method of claim 9 wherein the first and second core members are disposed on respective sheets, each sheet comprising a plurality of core members.
11. The method of claim 9 wherein the light comprises a light emitting diode.
12. The method of claim 9 wherein the first core member is secured to the second core member with an adhesive.
13. The method of claim 9 wherein the first core member is laminated to the second core member.
14. The method of claim 9 further comprising, subsequent to filling the cavity, milling the first core member to remove material filling the cavity flush with the second surface.
15. The method of claim 9 further comprising installing a battery in the cavity.
16. The method of claim 9 further comprising installing a switch in the cavity.
17. The method of claim 9 further comprising installing an electrical circuit in the cavity.
18. The method of claim 17 wherein installing the electrical circuit comprises printing at least a portion of the cavity with a conductive ink.
19. The method of claim 17 wherein installing the electrical circuit comprises depositing metallization in at least a portion of the cavity.
20. The method of claim 19 wherein installing the electrical circuit further comprises etching the metallization.
PCT/US2003/018736 2002-06-11 2003-06-11 Wallet card with built-in light WO2003105065A1 (en)

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CA002489152A CA2489152A1 (en) 2002-06-11 2003-06-11 Wallet card with built-in light
AU2003248689A AU2003248689A1 (en) 2002-06-11 2003-06-11 Wallet card with built-in light
BRPI0312135A BRPI0312135A2 (en) 2002-06-11 2003-06-11 wallet card with built-in light
EP03757501A EP1514220A4 (en) 2002-06-11 2003-06-11 Wallet card with built-in light
JP2004512062A JP2005530228A (en) 2002-06-11 2003-06-11 Wallet card with built-in light
MXPA04012575A MXPA04012575A (en) 2002-06-11 2003-06-11 Wallet card with built-in light.
IL165668A IL165668A (en) 2002-06-11 2004-12-09 Wallet card with built-in light

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US10/167,259 2002-06-11
US10/167,259 US6817532B2 (en) 1992-02-12 2002-06-11 Wallet card with built-in light

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EP (1) EP1514220A4 (en)
JP (1) JP2005530228A (en)
KR (1) KR20060021797A (en)
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AU (1) AU2003248689A1 (en)
BR (1) BRPI0312135A2 (en)
CA (1) CA2489152A1 (en)
IL (1) IL165668A (en)
MX (1) MXPA04012575A (en)
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