Regarding expired card.
The process of docs checking by IRN is long. First, IRN sends requests to so called “external organizations”. Those are AIMA, police (for internal criminal cases) and some portugal agency which deals with Interpol. Than it waits for answers. And only then analyze all documents - submitted and received answers.
You need valid card at the time when AIMA write an answer to IRN. Period. Otherwise AIMA gives negative responce to IRN. I have real examples with people who gets preliminary refusal because their card expired.
If you card is expiring during the process it is better to renew.
If you could not renew, do efforts to accumulate proofs that you have done everything to renew. In that case after you receive either request to submit new card or preliminary refusal, you may reply to IRN with proofs that it is not your fault and most likely IRN will give you time to renew. The process would be paused until you get new card.