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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 140°C
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
(160°C).
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
• No need for preparation
of sheet before printing
• Most accurate process
for colour reproduction
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!