Radio frequency identification card and hot lamination process for the manufacture of radio frequency identification cards
DCFirst Claim
1. A process for incorporating at least one electronic element in the manufacture of a plastic card, comprising the steps of:
- (a) providing first and second plastic core sheets;
(b) positioning said at least one electronic element in the absence of a non-electronic carrier directly between said first and second plastic core sheets to form a core, said plastic core sheets defining a pair of inner and outer surfaces of said core;
(c) positioning said core in a laminator apparatus, and subjecting said core to a heat and pressure cycle, said heat and pressure cycle comprising the steps of;
(i) heating said core for a first period of time;
(ii) applying a first pressure to said core for a second period of time such that said at least one electronic element is encapsulated by said core;
(iii) cooling said core while applying a second pressure to said core, (d) applying a layer of overlaminate film to at least one of said outer surfaces of said core.
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Accused Products
Abstract
A plastic card, such as a radio frequency identification card, including at least one electronic element embedded therein and a hot lamination process for the manufacture of radio frequency identification cards and other plastic cards including a micro-chip embedded therein. The process results in a card having an overall thickness in the range of 0.028 inches to 0.032 inches with a surface suitable for receiving dye sublimation printing—the variation in card thickness across the surface is less than 0.0005 inches. A card manufactured in accordance with the present invention also complies with all industry standards and specifications. Also, the hot lamination process of the present invention results in an aesthetically pleasing card. The invention also relates to a plastic card formed in accordance with the hot lamination process of the present invention.
147 Citations
16 Claims
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1. A process for incorporating at least one electronic element in the manufacture of a plastic card, comprising the steps of:
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(a) providing first and second plastic core sheets;
(b) positioning said at least one electronic element in the absence of a non-electronic carrier directly between said first and second plastic core sheets to form a core, said plastic core sheets defining a pair of inner and outer surfaces of said core;
(c) positioning said core in a laminator apparatus, and subjecting said core to a heat and pressure cycle, said heat and pressure cycle comprising the steps of;
(i) heating said core for a first period of time;
(ii) applying a first pressure to said core for a second period of time such that said at least one electronic element is encapsulated by said core;
(iii) cooling said core while applying a second pressure to said core, (d) applying a layer of overlaminate film to at least one of said outer surfaces of said core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
(a) positioning an overlaminate film on at least one surface of said core;
(b) subjecting said core to a second heat and pressure cycle comprising the steps of;
(i) heating said core to a temperature between approximately 175°
F. to 300°
F. for approximately 10 to 25 minutes;
(ii) applying approximately 1000 p.s.i. pressure to said core, and (iii) cooling said core to a temperature in the range of approximately 40°
F. to 65°
F. for approximately 10 to 25 minutes.
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11. The process for incorporating at least one electronic element in the manufacture of a plastic card as recited in claim 1, wherein said at least one electronic element is a micro-chip and an associated wire antenna.
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12. The process for incorporating at least one electronic element in the manufacture of a plastic card as recited in claim 1, wherein said at least one electronic element is a micro-chip and an associated circuit board antenna.
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13. The process for incorporating at least one electronic element in the manufacture of a plastic card as recited in claim 1, wherein said at least one electronic element is a read/write integrated chip and an associated antenna.
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14. A plastic card constructed in accordance with claim 1.
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15. A hot lamination process for the manufacture of plastic cards, said process comprising the steps of:
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(a) providing first and second plastic core sheets;
(b) positioning at least one electronic element in the absence of a non-electronic carrier directly between said first and second plastic core sheets to form a layered core;
(c) positioning said core in a laminator apparatus, and subjecting said core to a heat and pressure cycle, said heat and pressure cycle comprising the steps of;
(i) heating said core in said laminator, in the presence of a minimal first ram pressure, to a temperature which causes controlled flow of said plastic which makes up said first and second plastic core sheets;
(ii) applying a second pressure uniformly across said core for encapsulating said at least one electronic element within said controlled flow plastic;
(iii) subsequently cooling said core in conjunction with the concurrent application of a third pressure uniformly across said core, said core including and upper and lower surfaces. - View Dependent Claims (16)
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Specification