Oh my, what an idiot i've been. Thank you very much for your post!

I moved it up above my cache and it works just fine, here is what i've been able to shorten it down to now:

location ~* /card/ {
rewrite (?i)^/card/([a-zA-Z0-9_+]+)/(.*).png$ /card.php?name=$2&type=$1;
expires epoch;
}

Thank you to everyone who posted to help me, it's greatly appreciated!