HK1210301B - Information carrying card comprising crosslinked polymer composition, and method of making the same - Google Patents

Description

Information carrying card comprising a crosslinked polymer composition and method for making same

The present patent application claims the following benefits: U.S. provisional application No.13/801,677 filed on day 3, 13 in 2013, U.S. provisional application No.61/619,700 filed on day 4, 2012, and U.S. provisional application 61/696,604 filed on day 4, 9, 2012, the applications of which are expressly incorporated herein by reference.

Technical Field

The present disclosure relates to information carrying cards such as smart cards. More particularly, the disclosed subject matter relates to polymer compositions, information carrying cards including the compositions, and methods of making the same.

Background

The information carrying card provides identification, authentication, data storage, and application processing. Such cards or components include key cards, identification cards, phone cards, credit cards, bank cards, labels, bar code strips or other smart cards, and the like. Counterfeiting and information fraud associated with conventional plastic cards can result in billions of dollars of losses each year. In response, information carrying cards are becoming "smarter" to enhance security. Smart card technology provides a solution to prevent fraud and reduce the consequent losses.

Information carrying cards typically include an Integrated Circuit (IC), such as polyvinyl chloride (PVC), embedded in a thermoplastic material. Information has been entered and stored in the integrated circuit prior to the transaction. In use, the information carrying card operates in a "contact" mode or a "contactless" mode. In the contact mode, electronic components on the card are brought into direct contact with a card reader or other information receiving device to establish an electromagnetic coupling. In the contactless mode, the electromagnetic coupling between the card and the card reading device is established by electromagnetic action within a certain distance, without physical contact. The process of inputting information into the IC of an information carrying card also operates in either of these two modes.

As information carrying cards become "smarter," the amount of information stored on each card generally increases, and the complexity of the embedded IC also increases. The card also needs to be resistant to bending to protect sensitive electronic components from damage while providing good durability during use. It is also desirable to have a relatively simple and complete commercial process with improved productivity at low cost.

Disclosure of Invention

The present invention provides a core layer for an information carrying card comprising a crosslinked polymer composition, wherein the information carrying card is formed from a core layer comprising such a crosslinked polymer composition, and a method of making the information carrying card.

In some embodiments, a core layer for an information carrying card includes at least one thermoplastic layer having at least one cavity, an inlay layer, and a crosslinked polymer composition. At least a portion of the inlay layer is disposed in the at least one cavity of the at least one thermoplastic layer. The crosslinked polymer composition is disposed on the at least one thermoplastic layer and contacts the inlay layer. The inlay layer may include a laminate having at least one active or passive electronic component. For example, in some embodiments, the inlay layer includes at least one Light Emitting Diode (LED) component. The inlay layer may further include at least one of a metal-containing plate and a ceramic-containing plate. The crosslinked polymer composition is obtained from a crosslinkable polymer composition comprising a curable precursor. In some embodiments, such curable precursors or base units for crosslinking the polymer composition are selected from the group consisting of acrylates, methacrylates, urethane acrylates, silicone acrylates, epoxy acrylates, silicones, epoxies, and urethanes. The curable precursor may comprise a monomer, oligomer or prepolymer. The crosslinked polymer composition may or may not include any fillers. In additional embodiments, the information carrying card includes the core layer described above.

The present invention provides a method for forming a core layer for an information carrying card. In one embodiment, the method comprises the steps of: the method includes forming a first thermoplastic layer having at least one cavity, disposing at least a portion of an inlay layer in the at least one cavity, and dispensing a crosslinkable polymeric composition on the inlay layer. In some embodiments, the method further comprises the step of applying a vacuum to the crosslinkable polymeric composition. The crosslinkable polymer composition used in this process comprises a curable precursor in liquid form or in paste form. The crosslinkable polymeric composition may or may not include a filler. The method of making the core layer may further comprise affixing the inlay layer to the first thermoplastic layer prior to dispensing the crosslinkable polymeric composition. In a further embodiment, the method of making the core layer further comprises the step of curing said crosslinkable polymer composition to form a crosslinked polymer composition (e.g. at a predetermined temperature under pressure, optionally with radiation such as ultraviolet light).

The invention also provides a method for manufacturing an information carrying card comprising forming a core layer of an information carrying card of the invention. The method may further comprise heat laminating a printable thermoplastic film and a transparent thermoplastic film to each side of the core layer of the card.

Drawings

The present disclosure is better understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. In some instances, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Like numbers refer to like features throughout the specification and drawings.

Fig. 1-6 illustrate cross-sectional views of a layered structure at various steps in an exemplary process of forming a core layer of an information carrying card, in accordance with some embodiments.

Fig. 1 shows a cross-sectional view of a first release film.

Fig. 2 shows a cross-sectional view of a second release film disposed on the first release film of fig. 1.

Fig. 3 shows a cross-sectional view of a first thermoplastic layer having at least one cavity disposed on the two release films of fig. 2.

FIG. 4 is a cross-sectional view of the layers after the inlay layer is partially or fully disposed in the pocket of the first thermoplastic layer of FIG. 3.

FIG. 5 is a cross-sectional view of the layers after a cross-linkable polymer composition is dispensed into the inlay layer inside the cavity.

Fig. 6 is a cross-sectional view of the composite layer after placing a third or fourth release film on the layer of fig. 5.

Fig. 7 is a flow diagram illustrating an exemplary process of forming a core layer of an information carrying card according to some embodiments.

Fig. 8 is a flow diagram illustrating another exemplary process of forming a core layer of an information carrying card in accordance with some embodiments.

Fig. 9 is a flow chart illustrating an exemplary process of forming a thermoplastic layer with a cavity according to some embodiments.

Fig. 10-13 show cross-sectional views of the layered structure at different steps of the exemplary process in fig. 9.

Fig. 14 is a cross-sectional view of an exemplary core layer of an information carrying card made in accordance with the structure in fig. 1-6 and the steps in fig. 8.

Fig. 15 is a cross-sectional view of another exemplary core layer of an information carrying card at a final stage according to the steps in fig. 8 in some embodiments.

Fig. 16 is a cross-sectional view of an exemplary core layer of an information carrying card having a fully open cavity for an inlay according to some embodiments.

Fig. 17 is a top view of a core layer of the exemplary information carrying card of fig. 16.

Fig. 18 is a cross-sectional view of a core layer of an exemplary information carrying card having an open inlay nest with dimensions approximating those of an inlay, according to some embodiments.

Fig. 19 is a top view of a core layer of the exemplary information carrying card of fig. 18.

Fig. 20 is a cross-sectional view of a core layer of an exemplary information carrying card having a window cavity partially for an inlay, according to some embodiments.

Fig. 21 is a cross-sectional view of the core layer of the exemplary information carrying card of fig. 13.

Figures 22-25 illustrate an example process for securing an example inlay layer to a thermoplastic layer, according to some embodiments.

FIG. 22 is a top view of an exemplary inlay layer.

FIG. 23 is a top view of the exemplary inlay layer of FIG. 22 after being skived having holes in its support layer.

FIG. 24 is a top view of the exemplary inlay layer of FIG. 23 disposed on a thermoplastic layer.

FIG. 25 is a top view of the exemplary inlay layer of FIG. 24 secured to a thermoplastic layer using a quick-dry glue, according to some embodiments.

Figure 26 illustrates a flow diagram of an example process for securing an inlay layer to a thermoplastic layer, in accordance with some embodiments.

Fig. 27-31 show cross-sectional views of layer structures at different steps of an exemplary process of making an exemplary information carrying card, according to some embodiments.

FIG. 27 is a cross-sectional view of a transparent film.

FIG. 28 is a cross-sectional view of a printable film disposed on the transparent film of FIG. 27.

Fig. 29 is a cross-sectional view of the layer structure after an exemplary core layer is disposed on the two films of fig. 28.

FIG. 30 is a cross-sectional view of the composite layer structure after a second printable film is disposed on the layer structure of FIG. 29.

FIG. 31 is a cross-sectional view of the composite layer structure after a second transparent film is disposed on the layer structure of FIG. 30.

FIG. 32 is a flow chart illustrating an exemplary process of making an exemplary information carrying card.

Fig. 33 is a schematic diagram illustrating an exemplary core layer for a plurality of information carrying cards during an exemplary manufacturing process according to some embodiments.

Detailed Description

The description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as "lower," "upper," "horizontal," "vertical," "above," "below," "up," "down," "top," "bottom," and derivatives thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that any device be constructed or operated in a particular orientation. Unless clearly described otherwise, terms like "connected" and "interconnected" relating to attachment, coupling, and the like, refer to a relationship wherein structures are secured or attached to one another, either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships.

For the sake of brevity, unless otherwise expressly stated, references made throughout this specification to "information carrying cards" or "smart cards" are intended to include at least key cards, identification cards, phone cards, credit cards, bank cards, power cards, labels, bar code strips, and any components including integrated circuits. "information cards" or "smart cards" also include various types of shapes including, but not limited to, rectangular plates, circular plates, strips, rods, or rings. An "information card" or "smart card" also includes any information carrying components in "contact" and "contactless" modes. "information card" or "smart card" also includes any information carrying card with or without an onboard power source. Information carrying cards that include a power source are also referred to as "power cards".

1.Core layer of information carrying card

In some embodiments, the core layer of the information carrying card comprises at least one thermoplastic layer having at least one cavity; an inlay layer (inlay layer) and a cross-linked polymer composition. At least a portion of the inlay layer is disposed in the at least one cavity of the at least one thermoplastic layer. The crosslinked polymer composition is disposed on the at least one thermoplastic layer and contacts the inlay layer. In some embodiments, the crosslinked polymer composition is disposed into a cavity on at least one of the thermoplastic layers.

The crosslinked polymer composition may include a base unit selected from the group consisting of acrylates, methacrylates, urethane acrylates, silicone acrylates, epoxy acrylates, silicones, polyurethanes, epoxies, and the like. In some embodiments, the crosslinked polymer composition comprises a base unit selected from the group consisting of acrylates, methacrylates, urethane acrylates, silicone acrylates, and silicones. For example, the crosslinked polymer composition is an acrylate or a urethane acrylate. The crosslinked polymer may be unfilled or include fillers or additives, such as fillers in the range of about 0.5 wt.% to about 80 wt.%. The filler may be non-organic or organic. The crosslinked polymer composition is made by curing a crosslinkable polymer composition comprising a curable precursor. In some embodiments, the curable precursor is an acrylate, methacrylate, urethane acrylate, silicone acrylate, epoxy acrylate, silicone, polyurethane, epoxy resin, or the like.

In some embodiments, the inlay layer includes at least one active or passive electronic component, such as an Integrated Circuit (IC). For example, the inlay layer may include a Printed Circuit Board (PCB). In some embodiments, the inlay layer comprises a Light Emitting Diode (LED) assembly. At least one electronic component is partially or completely disposed in the cavity on the at least one thermoplastic layer. In some embodiments, the size of the at least one cavity on the first thermoplastic layer is greater than the size of the inlay layer. In some other embodiments, the size of the at least one cavity on the first thermoplastic layer is substantially the same as the size of the inlay layer. In some other embodiments, the size of the at least one cavity on the first thermoplastic layer is substantially the same as the size of a portion of the inlay layer. The inlay layer may also comprise a sheet of metal, ceramic, metal-containing material, ceramic-containing material, plastic, or the like. The core layer may also include a battery connected to at least one electronic component in the inlay layer.

The invention also provides a method of forming a core layer of such an information carrying card.

Referring to fig. 1 and 2, the first release film 2 may be referred to as a trade nameA sheet of teflon, any other fluoropolymer, silicone, fluoropolymer, or silicone coated film. The second release film 4 is disposed on the first release film 2. The second release film 4 may be formed of the same material and process as the first release film 2. In some embodiments, a breathable release film is preferred. An example of the breathable release film like the second release film 4 is a silicone coated paper. For example, the second release film 4 may take the form of a silicone-coated, unbleached parchment paper available under the trade name "If you care" from Regency Wraps. Two release films are shown for illustration only. In some embodiments, only one or no release film may be used.

Referring to fig. 3, the first thermoplastic layer 6 has at least one cavity 7, which cavity 7 is arranged on the release films 2 and 4. The first thermoplastic layer 6 may be molded or laminated from one or more thermoplastic layers. Examples of materials suitable for use in forming first thermoplastic layer 6 include polyvinyl chloride (PVC), vinyl chloride copolymers, polyolefins, polycarbonates, polyesters, polyamides, and Acrylonitrile Butadiene Styrene (ABS), among others. The first thermoplastic layer 6 may be PVC, or a copolymer of vinyl chloride and another monomer, such as vinyl ether or vinyl ester or vinyl acetate, or a PVC compound or blendAnd vinyl chloride polymers. Examples of PVC films suitable for use in the present invention may be utilized from the following suppliers: klockner Pentaplast, Inc., Gordonsville, Virginia, USA; china Shijia Eurochem, Inc. An example of such a copolymer resin is available from DOW chemical company under the trade name DOWAnd BASF from Ludwigshafen, Germany under the trade nameIs a copolymer of vinyl chloride and vinyl acetate. Grades include YNS-3, VYHH and VYHD.Is a copolymer of vinyl chloride and vinyl isobutyl ether. Grades include MP25, MP35, MP45, and MP 60. All of these polymer resins can be supplied as fine powders. Powders of these copolymers can be added to modify the PVC resin used for the film. The first thermoplastic layer 6 having at least one cavity may be formed by die cutting one or more thermoplastic layers and then laminating and heating the one or more thermoplastic layers.

Referring to fig. 4, at least a portion of inlay layer 8 is disposed in at least one cavity 7 of first thermoplastic layer 6. The inlay 8 is partially or completely arranged within the cavity 7. Inlay layer 8 includes at least one active or passive electronic component 10, which is embedded in or surface mounted on a support film 12. Inlay layer 8 may comprise a Printed Circuit Board (PCB). The electronic component 10 may be embedded or surface mounted on the PCB support material. Examples of support film 12 include, but are not limited to, polyimide, polyester such as PET, glass filled epoxy board such as FR-4. A Printed Circuit Board (PCB) with all components is simplified to a PCBa. For simplicity, in the present disclosure, references to PCBs are understood to include any PCB having PCBa. Examples of electronic components 10 within inlay layer 8 include, but are not limited to, active or passive electronic components, batteries such as Integrated Circuits (ICs), "power cards," antennas, functional components such as Light Emitting Diodes (LEDs). The electronic components are interconnected by wires or traces 14. The support film 12 may be a polymer-based dielectric material. Inlay layer 8 may have any size relative to the size of the cavity in first thermoplastic layer 6. Inlay layer 8 may be partially or completely disposed in such a cavity. In some embodiments, the size of the cavity on first thermoplastic layer 6 is greater than the size of inlay layer 8. Inlay layer 8 may be arranged completely in the cavity. In some embodiments, the size of the cavity in the first thermoplastic layer 6 is substantially equal to or slightly larger than the size of the inlay layer 6 of the PCB. The shape of the cavity generally matches the shape of inlay layer 8. In some embodiments, the size of the at least one cavity on first thermoplastic layer 6 is smaller than the size of inlay layer 8. The at least one cavity has a size substantially equal to or slightly larger than a portion of the inlay layer 8 of the PCB. For example, a cavity may be shaped and sized to mate with an electronic assembly 10. Examples of electronic components 10 include, but are not limited to, batteries or active electronic components or passive electronic components, such as Integrated Circuits (ICs) in inlay layer 8. In some embodiments, inlay layer 8 may comprise a plate or sheet of metal, ceramic, metal-containing material, ceramic-containing material, plastic, or the like. Examples of suitable materials for such sheets and plates include, but are not limited to, platinum, copper, tungsten, metallized powder-containing materials, alumina, silica, and ceramic-containing powder materials. Such sheets or plates may be of a particular color or weight to have a particular visual or other sensory characteristic.

Referring to fig. 5, after the cross-linkable polymer composition 16 is dispensed on inlay layer 8 in cavity 7 of first thermoplastic layer 6, the resultant layer is shown. In some embodiments, the crosslinkable polymeric composition 16 can also be dispensed on the first thermoplastic layer 6 outside the cavity. The crosslinkable polymeric composition 16 formed in accordance with the present invention generally includes a curable precursor in the form of a liquid or paste. Such curable precursors may be acrylates, methacrylates, urethane acrylates, silicone acrylates, epoxy acrylates, polyurethanes, epoxies, silicones, or the like. In some embodiments, the crosslinkable polymeric composition may be unfilled and in some other embodiments include fillers or other additives. The crosslinkable polymeric composition can include a filler in a range of about 0.5 wt.% to about 80 wt.%. The filler may be an inorganic filler or an organic filler. For example, the filler may be a particulate thermoplastic filler, such as a polyolefin, polyvinyl chloride (PVC), a copolymer of vinyl chloride and at least one other monomer, or a polyester such as polyethylene terephthalate (PET). In some embodiments, the at least another monomer in the vinyl chloride copolymer filler may be a vinyl ester, vinyl acetate, or vinyl ether. The particulate thermoplastic filler may be a compound or blend comprising a thermoplastic resin, for example a compound or blend comprising PVC.

The curable precursor in the crosslinkable polymer composition 16 can include a monomer, oligomer, or prepolymer having a functional group. The precursor may be crosslinkable under regular curing conditions including, but not limited to, heat, radiation such as Ultraviolet (UV) light, moisture, or other suitable conditions. The curable precursor may be in the form of a liquid or a paste. The viscosity is in the range of 1 to 100000 cps. In some embodiments, the curable precursor is a urethane acrylate. These curable precursors are readily available from specialty chemical suppliers. Examples of such suppliers include, but are not limited to, Dymax Copropation by Torrington, CT, and Sartomer USA by Exton, PA.

In some embodiments, a particulate thermoplastic filler may be used. Examples of thermoplastic fillers include, but are not limited to, polyolefins, PVC, polyesters, copolymers or terpolymers, and the like. The powdered polymer that provides sufficient results may be a compound or blend that includes PVC or modified PVC. The particulate thermoplastic filler may be a copolymer of vinyl chloride and at least one further monomer which may be vinyl ester, vinyl acetate or ethyleneAnd (c) an ether. An example of such a monomer may be referred to by the trade name UCAR from Dow chemical company^TMAnd BASF from Ludwigshafen, Germany under the trade name Laroflex^TM. UCARTM is a copolymer of vinyl chloride and vinyl acetate. Grades include YNS-3, VYHH and VYHD. Laroflex^TMIs a copolymer of vinyl chloride and vinyl isobutyl ether. Grades include MP25, MP35, MP45, and MP 60. All of these polymer resins are usually supplied as fine powders. The particulate thermoplastic filler may be obtained by suspension or emulsion polymerization of one or more corresponding monomers or by comminution of solid plastics. By way of example and not limitation, the particulate form may have any size. The particles may be in the range of 0.5 to 200 microns. In some embodiments, the particles are in the range of 1 to 1000 nanometers.

Based on the general principles of polymer chemistry, the crosslinkable polymer composition 16 may also include at least one curing agent. Such crosslinkable polymeric composition 16 becomes a solid crosslinkable polymeric composition 18 after curing. Preferably, in some embodiments, such a crosslinked composition 18 is more flexible than the first thermoplastic layer 6. For example, the crosslinkable polymeric composition 16 includes a first curing agent for thermal curing and a second curing agent for radiation curing. During the curing or crosslinking reaction, such crosslinkable compositions transform into solid crosslinked polymer compositions. Such a crosslinked polymer composition 18 is also referred to in the art as a "thermoset" polymer or "thermoset" to distinguish it from a thermoplastic polymer. In some embodiments, the crosslinkable polymeric composition is unfilled. In some other embodiments, the crosslinkable polymeric composition includes a filler in the range of about 0.5 wt.% to about 80 wt.% and preferably in the range of 5% wt. to 50 wt.%.

Examples of suitable crosslinkable polymeric compositions 16 include, but are not limited to, formulations including acrylates or urethane acrylates, for example. Examples of such a formulation include, but are not limited to, X-685-31-1 and X-685-31-2, which may utilize the Dymaxcorporation from Torrington, CT. X-685-31-1 is a formulation comprising isobornyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxy-3-phenoxypropyl acrylate, t-butyl perbenzoate and a photoinitiator. Its viscosity was 1047 cP. X-685-31-2 is also formulated to include isobornyl acrylate, hydroxyethyl 2-methacrylate, 2-hydroxy-3-phenoxypropyl acrylate, butyl t-perbenzoate, and photoinitiators. Its viscosity was 1025 cP. These formulations are dispensed on an inlay layer and then cured at a pressure of less than 2MPa at an elevated temperature of less than 150 degrees celsius. The resulting core layer and the resulting information carrying card are successfully produced. These examples are intended only to illustrate embodiments according to the invention and should not be construed as imposing limitations upon the claims.

The cross-linkable polymer composition 16 encased in the syringe is dispensed by using standard dispensing equipment or equipment for adhesives, encapsulants, sealants, and potting compounds. The amount of crosslinkable polymer composition 16 to be dispensed can be calculated and controlled based on the volume of the inlay layer 8 and the cavity.

In some embodiments, after being dispensed on first thermoplastic layer 6, crosslinkable polymer composition 16 is degassed in a vacuum chamber. In some embodiments, the degassing process by vacuum may be accomplished without any cover plates on the structure of fig. 5. Optionally, a second thermoplastic layer (not shown) is disposed on the structure of fig. 5 prior to the vacuum process. The second thermoplastic layer comprises a thermoplastic material selected from the group consisting of polyvinyl chloride, vinyl chloride copolymers, polyolefins, polycarbonates, polyesters, polyamides, and Acrylonitrile Butadiene Styrene (ABS). The second thermoplastic layer may be the same as the first thermoplastic layer 6. The thickness may be in the range of 0.025 to 0.25 mm. If used, the thermoplastic layer becomes part of the core layer. In other embodiments, at least one of the release films in fig. 6 is disposed on the structure of fig. 5 before the vacuum process.

Referring to fig. 6, after placing the third and fourth release films on the layers shown in fig. 5, the composite layer forms a sandwichAnd (5) structure. The third and fourth release films may be any type of release film, and in some embodiments, the second and third release films 4 are formed of the same material. The first and fourth release films 2 may also be formed of the same material. For example, in some embodiments, the second and third release films 2 may be formed of breathable silicon-coated paper. The first and fourth release films 4 are typically formed of a fluoropolymer, such as polytetrafluoroethylene, which is commonly known under the trade name TeflonTo provide. Two release films are shown for illustration purposes only. In some embodiments, only one or no release film may be used. The resulting sandwich or layered structure of fig. 6 is placed under pressure and heated to form a core layer for an information carrying card, as illustrated in the exemplary processes of fig. 7 and 8.

Referring to fig. 7, a process 20 of forming a core layer of an information carrying card according to some embodiments of the present invention includes the following steps. In step 24, a first thermoplastic layer 6 having at least one cavity 7 is formed. The first thermoplastic layer 6 with the at least one cavity 7 may be molded or laminated.

In some embodiments, the first thermoplastic layer 6 is formed by die cutting one or more thermoplastic films and then thermally laminating one or more uncut thermoplastic films. Such a first thermoplastic layer 6 may be made, for example, by using the process 61 shown in fig. 9. Cross-sectional views of the structures are shown in fig. 10 to 13. Referring to fig. 10, one or more thermoplastic films 63 are provided. The film 63 can have a thickness in the range of 0.025 to 0.5 millimeters. Referring to fig. 9, one or more thermoplastic films 63 are cut at step 62 to form the structure shown in fig. 11. At step 64 of fig. 9, one or more cut films 63 are placed on another thermoplastic film 65, resulting in the structure shown in fig. 12. Exemplary film 65 may have a thickness in the range of 0.025 to 0.25 millimeters. At step 66 of fig. 9, one or more combinations of films 63 and 65 are then laminated together to form a thermoplastic layer 6 having at least one cavity 7 as shown in fig. 13.

At step 27 of fig. 7, at least a portion of inlay layer 8 is disposed in at least one cavity 7. In some embodiments, the size of the at least one cavity on first thermoplastic layer 6 is greater than the size of inlay layer 8. In some embodiments, the size of the at least one cavity on the first thermoplastic layer 6 is substantially the same as the size of the inlay layer 8. In other embodiments, the size of the at least one cavity on the first thermoplastic layer 6 is substantially the same as the size of the inlay layer 8.

At optional step 30, inlay layer 8 is secured to first thermoplastic layer 6. In some embodiments, inlay layer 8 is secured to first thermoplastic layer 6 by using a quick-drying glue or welding. For example, in the absence of any electronic components 10 and interconnects 14, a plurality of holes are formed in inlay layer 8 by cutting away a portion of support layer 12. Quick-drying glue is applied to the wells. Examples of quick-drying glues include, but are not limited to, cyanoacrylate adhesives. Inlay layer 8 may be secured to first thermoplastic layer 6 for a short period of a few seconds.

At step 32 (fig. 7), the cross-linkable polymer composition 16 is dispensed on the inlay layer 8. In some embodiments, the crosslinkable polymeric composition 16 is dispensed into the cavity 17. The crosslinkable polymeric composition may be in direct contact with an electronic component 10 that includes an active electronic component or a passive electronic component, such as an Integrated Circuit (IC). The amount of the crosslinkable polymeric composition 16 is predetermined and controlled. Any additional material beyond the top surface of the first thermoplastic layer 6 may be removed. In some embodiments, the curable precursor in the crosslinkable polymeric composition 16 is not filled with an acrylate or urethane acrylate. In some embodiments, the crosslinkable polymeric composition includes a particulate thermoplastic filler such as PVC, a compound or blend including PVC, or a copolymer of vinyl chloride and at least another monomer (such as a vinyl ester or vinyl ether).

Process 20 may also include optional step 33. At step 33, a second thermoplastic layer is disposed on the first thermoplastic layer 6 after step 32. The second thermoplastic layer may be the same as the first thermoplastic layer 6. The thickness of the second thermoplastic layer may be in the range of 0.025 to 0.25 millimeters. If used, the thermoplastic layer becomes part of the core layer.

At step 35, a vacuum is applied to the crosslinkable polymeric composition 16 in a vacuum chamber. The pressure range is 10Pa to 1000 Pa. The vacuum may be maintained for 0.5 to 10 minutes, preferably 1 to 3 minutes. After the end of the cycle the vacuum is released. One or more cycles may be used to obtain a bubble-free sample. This vacuum process is performed at low temperatures, preferably at room temperature.

At step 37, at least one release film, such as release film 2 or 4 depicted in fig. 6, is disposed on the first thermoplastic layer 6. If a second thermoplastic layer is used, a release film 2 or 4 is placed on the second thermoplastic layer.

At step 39, the crosslinkable polymeric composition 16 is cured to form the crosslinked polymeric composition 18. The curing process may be obtained by a thermal curing method under pressure. Additional curing may be performed by a radiation curing mechanism.

Referring to fig. 8, a process 21 of forming a core layer of an information carrying card according to some embodiments of the invention includes the following steps. At step 22, the second release film 4 is placed on the first release film 2. At step 24, a first thermoplastic film 6 having at least one cavity is formed. The first thermoplastic layer 6 with the at least one cavity 7 may be molded or laminated. In some embodiments, the first thermoplastic layer 6 is formed by the steps of die cutting one or more thermoplastic films, and then thermally laminating one or more uncut thermoplastic films.

At step 26, a first thermoplastic layer 6 having at least one cavity is placed over the first and second release films (4 and 6). At step 28, the inlay layer 8 is placed at least partially in the at least one cavity on the first thermoplastic layer 6. Inlay layer 8 comprises a Printed Circuit Board (PCB). In some embodiments, the size of the at least one cavity on the first thermoplastic layer 6 is larger than the size of the inlay layer 8 of the PCB. In some embodiments, the size of the at least one cavity on the first thermoplastic layer 6 is the same as the size of the inlay layer 8 of the PCB. In other embodiments, the size of the at least one cavity on the first thermoplastic layer 6 is the same as the size of a portion of the inlay layer 8 of the PCB.

Following step 28, for example, the process optionally includes: the inlay is fixed 30 to the first thermoplastic layer 6 by using quick-drying glue or solder balls or the like. At step 32, the cross-linkable polymer composition 16 is dispensed on the inlay layer 8. At step 35, a vacuum is applied to eliminate any air bubbles in the crosslinkable polymeric composition 16.

At step 34, a third release film and a fourth release film 4 are placed on the layered structure to form a sandwich structure (fig. 6). The third release film is placed first and the fourth release film is placed subsequently. In some embodiments, the third release film is formed of the same material as that of the second release film 4, which is preferably a vented release film. The fourth release film may be formed of the same material as that of the first release film 2. In some embodiments, the first and fourth release films are polytetrafluoroethylene (trade name: polytetrafluoroethylene)) And (3) a plate. At step 36, the above layered structure is placed under pressure, such as a pressure of less than about 2 MPa.

At step 38, the layered structure is heated under pressure. Suitable temperatures are those that are sufficiently high to partially or fully cure the crosslinkable polymer composition 16, or to heat laminate the first thermoplastic layer film 6, or both. After the heat treatment, the crosslinkable polymeric composition 16 forms into a solid. This crosslinked polymer composition 18 has good adhesion to the first thermoplastic layer 6 and the inlay layer 8 comprising the electronic component 10 and the support film 12. In some embodiments, such a crosslinked composition is more flexible than the first thermoplastic film 6. In some embodiments, the temperature is in a range of 65 degrees celsius to 232 degrees celsius. In some embodiments, the temperature is less than 150 degrees celsius.

The process 21 may further include cooling the layer structure and peeling the first, second, third, and fourth release films. Process 21 may also include the step of curing the crosslinkable polymeric composition 16 using visible light, ultraviolet light, or other radiation curing. A step of curing by introduction of moisture or promotion of other chemical reactions may also be included. After process 21, the crosslinkable polymeric composition 16 is cured to produce a solid. After the release film is peeled off, a core layer for an information carrying card is formed. The core layer includes a first thermoplastic layer 6, an inlay layer 8, and a crosslinked polymer composition 18. Crosslinkable polymeric composition 16 becomes crosslinked polymeric composition 18 in a solid state. Different reference signs are used for differentiation purposes only, even though they may share the same chemical composition. An exemplary core layer for an information carrying card from process 21 is shown in fig. 14-21.

Referring to fig. 14, a core layer 80 of an exemplary information carrying card is manufactured according to the structure depicted in fig. 1 to 6 and according to the steps depicted in fig. 7 or fig. 8. More specifically, the exemplary core layer 80 includes a first thermoplastic layer 6, an inlay layer 8, and a crosslinked polymer composition 18. The first thermoplastic layer 6 is polyvinyl chloride (PVC), a vinyl chloride copolymer, a polyolefin, polycarbonate, polyester, polyamide, or Acrylonitrile Butadiene Styrene (ABS), or the like. Crosslinked polymeric composition 18 is formed from crosslinkable polymeric composition 16 described in the relevant section above. Inlay layer 8 includes an electronic component 10, such as at least one Printed Circuit Board (PCB), a support layer 12, and an interconnect 14. Electronic components, such as a battery and active or passive electronic components 10, are connected together using interconnects 14. The electronic component 10 is embedded on a support film 14. Crosslinked polymer composition 18 fills the voids and maintains the space within the cavities on first thermoplastic layer 6 and inlay layer 8. In some embodiments, crosslinked polymer composition 18 directly contacts the exterior surface of electronic assembly 10. Referring again to fig. 4, inlay layer 8 may have any size relative to the size of the cavity in first thermoplastic layer 6. Inlay layer 8 may be partially or fully disposed in such a cavity.

Referring to fig. 15, in some embodiments, a core layer 81 of another exemplary information carrying card at a final stage according to the steps in fig. 8 is shown. Similar to the core layer 80 of fig. 14. In some embodiments, a crosslinked polymeric composition 18 from the crosslinkable polymeric composition 16 is disposed on the first thermoplastic layer 6 outside the cavity 7, for example, having a thickness of 1 to 100 microns.

With reference to fig. 16 to 21, different configurations of the core layer for the information carrying card can also be utilized with good results. Referring to fig. 16, the core 82 of the exemplary information carrying card includes a fully open cavity for the inlay. In fig. 16 and 17, the size of the cavity on the first thermoplastic layer 6 is larger than the size of the inlay 8. In some embodiments, such cavities are close to, but slightly smaller than, the size of the information carrying card. Inlay layer 8 is arranged completely in the cavity. The shape of the cavity may be different from the shape of the inlay 8.

Referring to fig. 18 and 19, the core layer 86 of the exemplary information carrying card includes an open inlay cavity that approximates the size of inlay layer 8. In fig. 18 and 19, the size of the cavities on the first thermoplastic layer 6 is substantially equal to or slightly larger than the size of inlay layer 8. The shape of the cavity matches the shape of the inlay layer 8. In this configuration, inlay layer 8 may be disposed entirely within the cavity on first thermoplastic layer 6. The gap between the edge of the first thermoplastic layer 6 and the inlay layer 8 may be smaller than the gap shown in fig. 18 and 19.

Referring to fig. 20 and 21, the core 90 of the exemplary information carrying card includes a window cavity for the inlay. In fig. 20 and 21, the size of the at least one cavity on the first thermoplastic layer 6 is smaller than the size of inlay layer 8. The size of the at least one cavity is substantially equal to or slightly larger than the size of a portion of inlay layer 8. In some embodiments, a portion of the inlay layer is cut open to form one or more holes so that the electronic assembly 10 can be secured into one of the holes. Examples of such electronic components 10 include, but are not limited to, a chip or battery in inlay layer 8. In some embodiments, the electronic components 10 in the inlay layer 8 are inserted from one side of the first thermoplastic layer 6. During the manufacturing process, a cross-linkable polymer composition 16 for cross-linking the polymer composition 18 may be applied from the other side of the first thermoplastic layer 6.

Referring to fig. 22-26, an exemplary process 120 for securing the exemplary inlay layer 8 to the thermoplastic layer 6 using a quick-dry glue, according to some embodiments of the present invention, includes the following steps listed in fig. 26. An inlay layer is first provided. Referring to fig. 22, exemplary inlay layer 8 is used as a model for demonstration purposes. The electronic components used for the core layer of the information carrying card are not limited to those shown in fig. 22. Inlay layer 8 includes a support film 12, a battery 102, a chip 104 with at least one Integrated Circuit (IC), a metal structure 106, metal interconnect wires 108, and functional components such as LEDs 109. In some embodiments, support film 12 is a polymer-based dielectric material. This inlay layer is suitable for use in a "power card".

At step 122 (fig. 26), a plurality of holes are formed by cutting the inlay layer 8 on the portion of the support film 12 without any electronic components and interconnecting wires. Referring to fig. 23, the exemplary inlay 8 includes a plurality of holes 112 in its support layer 12 after being cut. The holes may be of any shape and size. Examples of the shape of the aperture include, but are not limited to, circular, rectangular, square, or any other shape. Step 122 is optional in some embodiments. The inlay layer is fixed to the first thermoplastic layer 6 without cutting holes.

In step 124 the resulting inlay layer 8 with holes is placed partly or completely in the cavity of the first thermoplastic layer 6. Exemplary inlay layer 8 may have any size relative to the size of the cavity in first thermoplastic layer 6. Exemplary inlay layer 8 may be partially or fully disposed into such a cavity. Referring to fig. 24, an exemplary inlay layer 8 having a plurality of holes is disposed on a first thermoplastic layer 6 having open inlay cavities. The exemplary first thermoplastic layer has a cavity that is larger than the inlay layer so that the inlay layer is completely disposed in the cavity on the first thermoplastic layer 6.

According to some embodiments, a small amount of quick-dry glue is applied to each well 112 at step 126. Referring to fig. 25, exemplary inlay layer 8 is secured to thermoplastic layer 6 by use of a quick-drying glue 115 to form a composite structure 116. Examples of the quick drying glue 115 include, but are not limited to, cyanoacrylate adhesives. In some embodiments, the quick-drying glue 115 cures quickly within a few seconds. Such a securing process used in this disclosure should be understood to include any process of securing inlay layer 8 to first thermoplastic layer 6 by using any type of adhesive.

2. Information carrying card

In some embodiments, an information carrying card includes the above-described core layer. In some embodiments, the information carrying card further comprises at least one printable thermoplastic film laminated to a surface of the core layer. In some embodiments, the information carrying card further comprises at least one transparent film laminated to the printable thermoplastic film. In some embodiments, the information carrying card further comprises at least one battery interconnected with the at least one electronic component in the inlay layer. The information carrying card further comprises at least one plate of metal, ceramic, metal-containing material, ceramic-containing material, plastic, or the like.

In some embodiments, the present invention also provides methods for manufacturing information carrying cards. In the present disclosure, the method includes forming a core layer of an information carrying card. The method may further comprise heat laminating the printable thermoplastic film and the transparent thermoplastic film to at least one side of the core layer of the information carrying card. In some embodiments, the printable thermoplastic film is laminated on one side of the core layer of the information carrying card. A transparent thermoplastic film is laminated to the printable thermoplastic film. In some embodiments, a printable thermoplastic film is laminated on each side of the core layer of the information carrying card. A transparent thermoplastic film is laminated to the printable thermoplastic film on each side of the core layer of the information carrying card.

Referring to fig. 27-32, an exemplary process 150 of making an exemplary information carrying card includes the following steps shown in fig. 32. The layer structure of the exemplary process 150 at various steps is shown in fig. 27 through 31. Referring to fig. 27, a transparent film 132 is first provided. Transparent film 132 may be used as an outer layer of an information carrying card. Examples of transparent film 132 include, but are not limited to, PVC and PET. In step 152 of fig. 32, referring to the structure shown in fig. 28, the printable thermoplastic film layer 134 is disposed on the transparent film 132. Printable thermoplastic film 134 is the image receiving layer. Words or images may be printed onto the printable thermoplastic film 134 prior to or during the process of making the information card. In some embodiments, this film is not transparent and includes some pigments, such as white pigments.

In step 154 of fig. 32, core layer 80 is disposed on printable thermoplastic film 134 and transparent film 132. One resulting exemplary layer is shown in fig. 29. Referring to fig. 14, in some embodiments, an exemplary core layer 80 includes a first thermoplastic layer 6, an inlay layer 8, and a crosslinked polymer composition 16. Inlay layer 8 includes an electronic component 10, such as at least one Printed Circuit Board (PCB), a support film 12, and interconnects 14. Electronic components, such as batteries and active or passive electronic components 10, are connected with the interconnect 14. The electronic component 10 is embedded or surface mounted on a support film 14. Crosslinked polymer composition 16 fills the voids and maintains the space within the cavities on first thermoplastic layer 6 and inlay layer 8. In some embodiments, crosslinked polymer composition 18 directly contacts the exterior surface of electronic assembly 10.

In step 156 (fig. 32), a second printable thermoplastic layer 134 is disposed onto the layered structure of fig. 29, followed by a second transparent film 132. Exemplary resulting layer structures are shown in fig. 30 and 31. In some embodiments, at least one release film is used on each side of the layer structure of fig. 31. Referring to fig. 1 and 2, examples of release films include a sheet of polytetrafluoroethylene, any other fluoropolymer, silicone, fluoropolymer-coated, or silicon-coated film.

In step 158 (fig. 32), the exemplary layer structure after step 156 is laminated under pressure at an elevated temperature. The layered structure after step 156 is pressed under pressure. In some embodiments, the pressure is less than 2 MPa. The layered sandwich structure is then heated under pressure at an elevated temperature. The suitable temperature is high enough that all the films are laminated with good adhesion. In some embodiments, the temperature is in a range of 65 degrees celsius to 232 degrees celsius. In some embodiments, the temperature is less than 150 degrees celsius. In some embodiments, the information carrying cards may have different sizes. In some embodiments, the information carrying card may have dimensions that conform to the ISO/IEC7810 standard. For example, the ID-1 type smart card for most bank cards and ID cards has dimensions of 85.6 x 53.98 mm.

In some embodiments, the exemplary process 150 includes a process such as a surface treatment to improve adhesion between two layers. Examples of surface treatment methods include, but are not limited to, plasma treatment or corona treatment prior to thermal lamination at step 158.

Exemplary processes 20 (or 21) and 150 may be used to fabricate multiple information carrying cards on one board, according to some embodiments of the present invention. Referring to fig. 33, in such a process, the first thermoplastic layer 6 comprises a plurality of cavities, wherein the inlay layer 8 is partially or completely arranged in each cavity. Referring to fig. 33, like items are denoted by like reference numerals, and the description of the structure provided above with reference is also described above.

An exemplary core structure 180 including a plurality of inlay layers 8 may be fabricated using processes 20 and 21 as described above. In some embodiments, each inlay layer 8 is secured to first thermoplastic layer 6 with a quick-dry glue 115 using an exemplary process 120 (fig. 26). Each inlay layer 8 is cut with a plurality of holes before the quick drying glue 115 is used. Referring to fig. 4, in some embodiments, exemplary core layer 80 further includes crosslinked polymer composition 18. Inlay layer 8 includes electronic components 10, such as at least one Printed Circuit Board (PCB), a support film 12, and interconnects 14. Crosslinked polymer composition 18 fills the voids and maintains the space within the cavities on first thermoplastic layer 6 and inlay layer 8. In some embodiments, crosslinked polymer composition 18 directly contacts the exterior surface of electronic assembly 10.

Referring to fig. 5, a cross-linkable polymer composition 16 is disposed on the inlay layer within each cavity to form a cross-linked polymer composition 18. Exemplary crosslinkable polymeric compositions include curable precursors with or without fillers. The curable precursor is urethane acrylate, silicone acrylate, epoxy acrylate, acrylate including methacrylate, silicone, polyurethane, epoxy resin, or the like. The crosslinkable polymeric composition 16 is cured to form a crosslinked polymeric composition 18. Examples of curing methods include, but are not limited to, thermal curing and radiation curing. In some embodiments, thermal curing occurs during the thermal lamination process.

In some embodiments, the exemplary core structure 180 is further laminated with at least one printable thermoplastic layer and a transparent film. The resultant laminated structure is then cut to form a plurality of information carrying cards. In some embodiments, the pressure is preferably less than 2 MPa. In some embodiments, the temperature is in the range of 65 degrees celsius to 232 degrees celsius, and in some embodiments of the lamination process is preferably less than 150 degrees celsius.

The rectangular information carrying card or smart card in this disclosure is for illustration only. The disclosed structures and fabrication processes are also applicable to any information carrying card or component of any shape and size. Examples of such components include, but are not limited to, rectangular plates, circular plates, strips, rods, or rings. Dimensions include, but are not limited to, any dimensions that comply with the ISO/IEC7810 standard.

While the subject matter has been described in terms of exemplary embodiments, it is not so limited. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.

Claims (24)

1. A method for forming a core layer of an information carrying card comprising:

forming a first thermoplastic layer defining at least one cavity therein, the at least one cavity having a continuous surface profile defined by and within the first thermoplastic layer, wherein the first thermoplastic layer comprises at least one thermoplastic material;

disposing at least a portion of an inlay layer into the at least one cavity; and is

A crosslinkable polymeric composition is dispensed on the first thermoplastic layer and at least partially into the at least one cavity and contacts the inlay layer such that a core layer of the information carrying card is formed.

2. The method of claim 1, wherein the crosslinkable polymeric composition comprises:

a curable precursor selected from the group consisting of acrylates, methacrylates, urethane acrylates, silicone acrylates, epoxy acrylates, methacrylates, silicones, urethanes, and epoxies, and

the crosslinkable polymer composition is a liquid or a paste.

3. The method of claim 1, further comprising:

applying a vacuum to the crosslinkable polymeric composition.

4. The method of claim 3, further comprising:

disposing a second thermoplastic layer on the first thermoplastic layer after dispensing the crosslinkable polymeric composition.

5. The method of claim 4, wherein the first or second thermoplastic layer comprises a thermoplastic material selected from the group consisting of polyvinyl chloride, vinyl chloride copolymers, polyolefins, polycarbonates, polyesters, polyamides, and Acrylonitrile Butadiene Styrene (ABS).

6. The method of claim 3, further comprising:

disposing a release film on the first thermoplastic layer; and is

Curing the crosslinkable polymeric composition to form a crosslinked polymeric composition.

7. The method of claim 6, wherein curing the crosslinkable polymer composition is performed under heat or ultraviolet light.

8. The method of claim 3, further comprising:

arranging a first release film;

placing a second release film on the first release film; and is

Placing a first thermoplastic layer having at least one cavity defined therein on the second release film prior to disposing at least a portion of the inlay layer into the at least one cavity.

9. The method of claim 8, further comprising:

placing a third release film on the first thermoplastic layer after dispensing the crosslinkable polymeric composition; and is

Placing a fourth release film on the third release film and forming a sandwich structure.

10. The method of claim 9, the second and third release films being ventable release films.

11. The method of claim 9, further comprising:

pressing the sandwich structure under pressure; and is

Heating the sandwich structure at an elevated temperature under said pressure.

12. The method of claim 11, wherein the pressure is less than 2MPa and the elevated temperature is less than 150 degrees celsius.

13. The method of claim 1, further comprising:

securing the inlay layer to the first thermoplastic layer prior to dispensing the crosslinkable polymeric composition.

14. The method of claim 1, wherein forming the first thermoplastic layer defining at least one cavity therein comprises:

die cutting one or more thermoplastic films; and is

Laminating the one or more thermoplastic films under heated conditions.

15. The method of claim 1, wherein the inlay layer comprises at least one electronic component, wherein the at least one electronic component is partially or fully disposed on the at least one thermoplastic layer in the cavity.

16. The method of claim 15, wherein the at least one electronic component in the inlay layer comprises at least one integrated circuit.

17. The method of claim 15, wherein the at least one electronic component in the inlay layer comprises at least one Light Emitting Diode (LED) component.

18. The method of claim 15, wherein a battery is connected with the at least one electronic component.

19. The method of claim 1, further comprising disposing at least one of a metal-containing plate and a ceramic-containing plate within a core layer of the information carrying card.

20. A method for manufacturing an information carrying card comprising forming a core layer of the information carrying card according to claim 1.

21. The method of claim 20, further comprising

After curing the crosslinkable polymeric composition to form a crosslinked polymeric composition, a printable thermoplastic film is laminated on one side of the core layer of the information carrying card.

22. The method of claim 21, further comprising

Laminating a transparent thermoplastic film to said printable thermoplastic film on one side of the core layer of said information carrying card.

23. A method according to claim 21 wherein a printable thermoplastic film is laminated on each side of the core layer of the information carrying card.

24. A method according to claim 23 wherein a transparent thermoplastic film is laminated over the printable thermoplastic film on each side of the core layer of the information carrying card.