# US 11,993,065 B2 · Metal card manufacturing method

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- Number: US 11,993,065 B2
- Document ID: US11993065B2
- Status: Granted
- Kind: B2
- Application number: 17/254,692
- Filed: 2018-06-20
- Published: 2021-06-10
- Granted: 2024-05-28
- Earliest claimed: 2018-06-20
- Assignees: Kona I Co., Ltd.; Kona M Co., Ltd.
- Applicants: Kona I Co., Ltd.; Kona M Co., Ltd.
- Inventors: Ki sung Nam; Han seon Kim; Suk Ku Lee
- Web page: https://patentgrep.com/patent/US11993065B2

## CPC

- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B26D 7/088: {by cleaning or lubricating (sterilizing B26D1/00)}
- B26F 1/3813: {wherein the tool head is moved in a plane parallel to the work in a coordinate system fixed with respect to the work}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/041: {of metal}
- B32B 15/092: comprising epoxy resins
- B32B 15/16: next to a particulate layer
- B32B 27/38: comprising epoxy resins
- G06K 19/02: characterised by the selection of materials, e.g. to avoid wear during transport through the machine
- G06K 19/077: Constructional details, e.g. mounting of circuits in the carrier
- G06K 19/07722: {the record carrier being multilayered, e.g. laminated sheets (flat articles in general, see B32B37/00)}
- G06K 19/07749: {the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card}
- B32B 38/10: Removing layers, or parts of layers, mechanically or chemically
- B32B 2250/05: 5 or more layers
- B32B 2260/025: Particulate layer
- B32B 2260/046: Synthetic resin
- B32B 2307/206: Insulating
- B32B 2307/208: Magnetic, paramagnetic
- B32B 2307/212: Electromagnetic interference shielding
- B32B 2307/732: Dimensional properties
- B32B 2425/00: Cards, e.g. identity cards, credit cards
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B26D: CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING (for growing crops or plants A01D, A01G; for fodder or straw A01F; for bulk butter A01J; for dough A21C; slaughtering A22B; for tobacco, cigars or cigarettes A24; marking-out, perforating or making buttonholes A41H25/00; manufacturing footwear A43D; brushmaking A46D; surgery A61B; disintegrating, mincing or shredding in general B02C; cutting wire, making pins or nails B21F, B21G; of the kind used formetal B23; cutting by abrasive fluid jets B24C5/02; hand-held cutting tools B26B; perforating, cutting-out, stamping-out or punching, or severing by means other than cutting B26F; for wood B27; for stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; article or web delivery apparatus incorporating cutting or line-perforating devices B65H35/00; for leather or upholstery B68, C14B; for glass C03B; making matches C06F; for peat C10F; for sugar C13B45/00; for textile materials D06H; civil engineering, building, mining, see Section E; for light guides G02B6/25; cutting processed photographic material G03D15/04)
- B26F: PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING (marking-out, perforating or making buttonholes A41H25/00; shoemaking A43D; surgery A61B; punching metal B21D; drilling metal B23B; cutting of metal by applying heat locally, e.g. flame cutting, B23K; cutting by abrasive fluid jets B24C5/02; details common to machines for severing B26D; drilling wood B27C; drilling stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; of glass C03B; of leather C14B; of textile materials D06H; for light guides G02B6/25; of tickets G07B)
- G06K: GRAPHICAL DATA READING (image or video recognition or understanding G06V); PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS

## Abstract

The present invention relates to a metal card manufacturing method including the steps of: preparing a metal sheet having a given size capable of accommodating a plurality of individual cards; preparing a ferromagnetic insulating sheet made by containing epoxy in a ferrite to the same size capable of accommodating the plurality of individual cards as the metal sheet; preparing an inlay sheet on which antenna coils are printed to the same size as the insulating sheet and forming holes on at least one or more edges of stacked sheets formed by stacking a plurality of sheets inclusive of the insulating sheet and the inlay sheet; fitting the holes formed on the stacked sheets to pins located on a loading plate; placing the metal sheet on top of the stacked sheets; forming a metal card sheet through lamination among the metal sheet and the stacked sheets; and cutting the metal card sheet along individual card outlines of the plurality of individual cards.

## Claims

### Claim 1

A metal card manufacturing method comprising steps of:
providing a metal sheet having a given size capable of accommodating a plurality of individual metal cards;
providing a ferromagnetic insulating sheet made by containing epoxy in a ferrite to a same size as the metal sheet capable of accommodating the plurality of individual metal cards;
providing an inlay sheet and printing antenna coils on the inlay sheet wherein the printed antenna coils are formed directly adjacent to the insulating sheet; stacking a plurality of sheets inclusive of the insulating sheet and the inlay sheet while forming holes on at least one or more edges of the stacked sheets formed;
fitting the holes formed on the stacked sheets to a plurality of pins located on a loading plate of a cutting tool;
placing the metal sheet on top of the stacked sheets;
forming a metal card sheet through lamination among the metal sheet and the stacked sheets;
forming outlines for the individual metal cards; and
cutting the metal card sheet based on the individual card outlines to form the plurality of individual metal cards,
wherein the cutting the metal card sheet further comprises injecting cooling alcohol while cutting the individual card outlines by the cutting tool in a Computerized Numerical Control (CNC) process.

### Claim 2 (depends on 1)

The metal card manufacturing method according to claim 1, wherein the forming holes on at least one or more edges of the stacked sheets comprises step of punching the holes on positions adjacent to peaks at which the two or more edges of the stacked sheets meet.

### Claim 3 (depends on 2)

The metal card manufacturing method according to claim 2, further comprising step of replacing the cutting tool with a new one when cutting operations for the individual card outlines are performed over a predetermined number of times set in advance.

### Claim 4 (depends on 2)

The metal card manufacturing method according to claim 2, wherein the providing the metal sheet comprises:
forming holes on at least one or more edges of the metal sheet; and
forming insertion spaces on an underside of the metal sheet coming into contact with the stacked sheets through a CNC process.

### Claim 5 (depends on 4)

The metal card manufacturing method according to claim 4, wherein the providing the metal sheet further comprises step of inserting machined layers made of a plastic material into the insertion spaces.

### Claim 6 (depends on 5)

The metal card manufacturing method according to claim 5, wherein the providing the metal sheet further comprises step of forming machined layer exposure portions on an opposite side surface to the metal sheet side on which the machined layers are inserted.

### Claim 7 (depends on 6)

The metal card manufacturing method according to claim 6, wherein the cutting the metal card sheet further comprises step of cutting chip exposure areas having a smaller width than the machined layer exposure portions and located inside the individual card outlines to allow the antenna coils of the inlay sheet to be exposed to an outside.