Advanced smart cards with integrated electronics in bottom layer and method of making such advanced smart cards
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1. An advanced smart card comprising a top layer, a core layer of thermoset polymeric material, and a bottom layer comprising an integrated electronics assembly mounted on a substrate formed according to the following steps:
- (1) positioning a bottom layer comprising the integrated electronics assembly mounted on a substrate in a bottom mold;
(2) positioning a top layer comprising synthetic paper or other plastic material in a top mold;
(3) closing the top mold to the bottom mold in a manner that creates a void space between the top layer and the bottom layer comprising the integrated electronics assembly;
(4) injecting a thermosetting polymeric material into the void space to form a core layer consisting of polymeric material, the injection taking place at a temperature and pressure which are such that;
(a) the top layer of material is at least partially cold, low pressure molded into a cavity in the top mold;
(b) gases and excess polymeric material are driven out of the void space;
(c) the injected polymeric material flows over and around all exposed portions of the electronic components of the integrated electronic assembly positioned on the top surface of the bottom layer such that the bottom surface of the bottom layer remains free of the injected polymeric material and;
(d) the thermosetting polymeric material bonds with both the top layer and the bottom layer to produce a unified precursor advanced smart card body;
(5) removing the unified precursor advanced smart card body from the top and bottom molds; and
(6) trimming the precursor advanced smart card to a desired dimension to produce a finished advanced smart card.
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Abstract
An advanced smart card with a top layer, a core layer of thermoset polymeric material, and a bottom layer comprising an integrated electronics assembly mounted on a substrate. The advanced smart card is formed by positioning a bottom layer in a bottom mold, placing a top layer in a top mold, closing the mold, injecting a thermosetting polymeric material to form a precursor advanced smart card, removing the precursor, and trimming the precursor to produce a finished smart card.
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Citations
15 Claims
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1. An advanced smart card comprising a top layer, a core layer of thermoset polymeric material, and a bottom layer comprising an integrated electronics assembly mounted on a substrate formed according to the following steps:
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(1) positioning a bottom layer comprising the integrated electronics assembly mounted on a substrate in a bottom mold; (2) positioning a top layer comprising synthetic paper or other plastic material in a top mold; (3) closing the top mold to the bottom mold in a manner that creates a void space between the top layer and the bottom layer comprising the integrated electronics assembly; (4) injecting a thermosetting polymeric material into the void space to form a core layer consisting of polymeric material, the injection taking place at a temperature and pressure which are such that; (a) the top layer of material is at least partially cold, low pressure molded into a cavity in the top mold; (b) gases and excess polymeric material are driven out of the void space; (c) the injected polymeric material flows over and around all exposed portions of the electronic components of the integrated electronic assembly positioned on the top surface of the bottom layer such that the bottom surface of the bottom layer remains free of the injected polymeric material and; (d) the thermosetting polymeric material bonds with both the top layer and the bottom layer to produce a unified precursor advanced smart card body; (5) removing the unified precursor advanced smart card body from the top and bottom molds; and (6) trimming the precursor advanced smart card to a desired dimension to produce a finished advanced smart card. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. An advanced smart card comprising a top layer, a core layer of thermoset polymeric material, and a bottom layer comprising an integrated electronics assembly mounted on a substrate formed according to the following steps:
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(1) using an integrated electronics assembly mounted on a substrate, with maximum dimensions of 54 mm wide, 85.6 mm long, and 0.50 mm thick, and positioning the integrated electronics assembly mounted on a substrate in a bottom mold; (2) positioning a top layer comprising synthetic paper or other plastic material in a top mold; (3) closing the top mold to the bottom mold in a manner that creates a void space between the top layer and the bottom layer comprising the integrated electronics assembly; (4) injecting a thermosetting polymeric material into the void space to form a core layer consisting of polymeric material, the injection taking place at a temperature less than 150°
F. and pressure less than 100 PSI which are such that;(a) the top layer of material is at least partially cold, low pressure molded into a cavity in the top mold; (b) gases and excess polymeric material are driven out of the void space; (c) the injected polymeric material flows over and around all exposed portions of the electronics components of the integrated electronics assembly positioned on the top surface of the bottom layer such that the bottom surface of the bottom layer remains free of the injected polymeric material; and (d) the thermosetting polymeric material bonds with both the top layer and the bottom layer to produce a unified precursor advanced smart card body; (5) removing the unified precursor advanced smart card body from the top and bottom molds; and (6) trimming the precursor advanced smart card to a desired dimension to produce a finished advanced smart card. - View Dependent Claims (15)
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Specification