CREDIT CARDS

Overview

INTRODUCTION

History

Initially not made into a card

First issued around 1865 Initially made of celluloid Later ones were made of copper, aluminium, steel or white metal, which is when they became known as charge coins/ charge plates

Uses

Issued by banks that allow consumers to make purchases on credit.

REQUIRED PROPERTIES OF MATERIAL

Durable Recyclable Economical efficiency low-cost material Weathering stability Resistance to degradation

CURRENTLY

Polyvinyl chloride (PVC), a thermo-plastic polymer.

Low price, recycling possible

High hardness and mechanical properties.

Highly versatile polymer

Limited thermal stability, decomposes at 140C

PVC is also a durable material and is not affected by corrosion or other forms of degradation

PVC PROPERTIES
Mechanical properties enhanced with stabilizers and additives PVC materials are divided into two classes: rigid and flexible PVC (pipes & Tubes). Credit cards are considered rigid PVC.

FLAMMABILITY AND THE OXYGEN INDEX

Oxygen index to measure flammability Compound that is easily flammable will burn with a smaller amount of oxygen, hence it has a relatively low oxygen index.

CREDIT CARDS: OXYGEN INDEX OF PVC

Rigid PVC has an oxygen index of 45

Relatively less flammable than many other materials

The oxygen index for wood is around 20-25, polyethylene or polypropylene also have lower oxygen indexes (around 20)

BURNING CREDIT CARDS: POSSIBLE DANGERS

Although PVC has a higher oxygen index, this does not mean it cannot catch fire. Gases formed when burning the credit cards can be quite dangerous.

Addition of fire retardants to help increase the resistance to fire

COMPARISON OF THE MATERIALS USED

TECHNOLOGY INJECTION MOLDING (COMPONENTS)

TECHNOLOGY INJECTION MOLDING (CYCLE)

First stage

TECHNOLOGY INJECTION MOLDING (MELTING POLYMER)

Plastic materials are supplied in the form of small pellets into the hopper The pellets are then gravity fed from the hopper to the barrel

TECHNOLOGY INJECTION MOLDING (SCREW)

TECHNOLOGY INJECTION MOLDING (SCREW)

Feeding zone: Pellets crushed together Air ejected Transition zone: Melted by mechanical shear Metering zone Melted polymer is homogenized Ready for injection Screw moves forward to inject plastic into mold cavity

TECHNOLOGY INJECTION MOLDING (NOZZLE)

Nozzle temperature set to the materials melt temperature (160C).

TECHNOLOGY INJECTION MOLDING (INJECTION)

The melt converges at a nozzle and is injected into the mold. The melt is forced into the mold in three stages: Fill stage (mold cavities are filled with molten resin) Pack stage (force more melt into the mold to compensate for shrinkage during cooling) Hold stage (applies forces against the material in the cavity until the gate freezes to prevent leaking of the melt)

TECHNOLOGY INJECTION MOLDING (COOLING)

Water is circulated in cooling system to remove heat The air trapped in the cavity passes through narrow vents Mold opens Ejection pins move forward to eject part Mold closes Process starts again

TECHNOLOGY INJECTION MOLDING (CONCERNS)

Mold cavity not filled up before solidifying Shrinking of the plastic resulting in sink holes Quality control essential to ensure product quality

TECHNOLOGY - PRINTING

Offset printing Screen printing Digital printing

TECHNOLOGY PRINTING (OFFSET PRINTING)

TECHNOLOGY PRINTING (SCREEN PRINTING)

TECHNOLOGY PRINTING (DIGITAL PRINTING)

Digital printers working with thermal sublimation dye or retransfer printing are used to print individual designs onto white cards.
Quality of this technique has not reached the level of Offset or Screen Printing Results are well accepted by card issuers.

BENEFITS OF PRINTING TECHNOLOGY

Offset Printing and Screen Printing Digital Printing

Most cost effective when printing more than 1,000 copies

Most accurate process for colour reproduction

No need for preparation of sheet before printing

TECHNOLOGY - LAMINATION

Consist of two or more foils, which are pressed together under high temperatures Foils are of thermoplastic material, connects under heat when softening temperature is reached For external printing, the surface will be covered by a transparent varnish For internal printing, transparent overlay foils will be laminated over the design which provides a better resistance against scratching and abrasion

ADDING MAGNETIC STRIPE AND SIGNATURE PANELS

Magnetic stripe comes in an overlay foil and is laminated Paper signature panels are mounted to the outside overlay foil of a card and will connect to the card surface during the lamination process

ADDED SECURITY MEASURES

VIDEO

CONCLUSION

The chosen material is rigid PVC

Manufacturing process involves
Injection

Molding

Printing

Lamination

Q&A

Thank you!