Information carrying card comprising crosslinked polymer composition, and method of making the same

Patent metadata

Field	Value
Publication number	US-10127489-B2
Application number	US-201715421938-A
Country	US
Kind code	B2
Filing date	Feb 1, 2017
Priority date	Apr 3, 2012
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

The disclosure provides a core layer for an information carrying card, resulting information carrying card, and methods of making the same. A core layer for an information carrying card comprises at least one thermoplastic layer having at least one cavity, an inlay layer, and, and a crosslinked polymer composition. At least one portion of the inlayer layer is disposed inside the at least one cavity of the at least one thermoplastic layer. The crosslinked polymer composition is disposed over the at least one thermoplastic layer and contacting the inlayer layer.

First claim

What is claimed is:

1. A core layer for a plurality of information carrying cards, comprising
a first thermoplastic layer defining a plurality of cavities therein, each cavity having a continuous surface profile solely defined by and inside the first thermoplastic layer, the continuous surface profile having a bottom wall surface and a side wall surface;
a plurality of inlay layers, each inlay layer having at least one portion being disposing into one respective cavity; and
a crosslinked polymer composition disposed in each of the plurality of cavities and contacting the pluralities of inlay layers.

2. The core layer of claim 1 , wherein the crosslinked polymer composition comprises a polymer selected from the group consisting of acrylate, methacrylate, urethane acrylate, silicone acrylate, epoxy acrylate, methacrylate, silicone, urethane and epoxy.

3. The core layer of claim 1 , wherein the crosslinked polymer composition comprises a urethane acrylate or epoxy.

4. The core layer of claim 1 further comprising a second thermoplastic layer disposed above the first thermoplastic layer.

5. The core layer of claim 4 wherein the first or second thermoplastic layer comprises a thermoplastic material selected from the group consisting of polyvinyl chloride, copolymer of vinyl chloride, polyolefin, polycarbonate, polyester, polyamide, and acrylonitrile butadiene styrene copolymer (ABS).

6. The core layer of claim 1 wherein the inlay layer comprises at least one electronic component comprising at least one of an integrated circuit, a light emitting diode (LED) component, and a battery.

7. A method for forming a core layer for a plurality of information carrying cards, comprising:
forming a first thermoplastic layer defining a plurality of cavities therein, each cavity having a continuous surface profile defined solely by and being inside the first thermoplastic layer, the continuous surface profile having a bottom wall surface and a side wall surface;
disposing a plurality of inlay layers into the plurality of cavities, each inlay layer having at least one portion being disposing into one respective cavity; and
dispensing a crosslinkable polymer composition over the first thermoplastic layer and at least partially into each of the plurality of cavities, and contacting the pluralities of inlay layers so as to form the core layer for the plurality of information carrying cards.

8. The method of claim 7 , wherein the crosslinkable polymer composition comprises:
a curable precursor, the curable precursor selected from the group consisting of acrylate, methacrylate, urethane acrylate, silicone acrylate, epoxy acrylate, methacrylate, silicone, urethane and epoxy, and
the crosslinkable polymer composition is a liquid or a paste.

9. The method of claim 7 , wherein the crosslinkable polymer composition comprises urethane acrylate and epoxy.

10. The method of claim 7 further comprising
applying vacuum to the crosslinkable polymer composition.

11. The method of claim 7 further comprising
disposing a second thermoplastic layer above the first thermoplastic layer after dispensing the crosslinkable polymer composition.

12. The method of claim 11 wherein the first or second thermoplastic layer comprises a thermoplastic material selected from the group consisting of polyvinyl chloride, copolymer of vinyl chloride, polyolefin, polycarbonate, polyester, polyamide, and acrylonitrile butadiene styrene copolymer (ABS).

13. The method for claim 7 further comprising:
providing at least one release film above the first thermoplastic layer; and
curing the crosslinkable polymer composition to form a crosslinked polymer composition under heat or UV light.

14. The method of claim 13 further comprising:
pressing a resulting the sandwich structure under a pressure; and
heating the sandwich structure at a raised temperature less than 150° C. under the pressure less than 2 MPa.

15. The method of claim 7 further comprising:
fixing the inlay layer onto the first thermoplastic layer, before dispensing the crosslinkable polymer composition.

16. The method of claim 7 wherein forming the first thermoplastic layer defining at least one cavity therein comprises:
die-cutting one or more thermoplastic films; and
laminating the one or more thermoplastic films under a heating condition.

17. The method of claim 7 wherein the inlay layer comprises at least one electronic component, wherein the at least one electronic component is partially or fully disposed inside the cavity over the at least one thermoplastic layer.

18. The method of claim 17 wherein the at least one electronic component in the inlay layer comprises at least one of an integrated circuit, a light emitting diode (LED) component, and a battery.

19. A method for fabricating a plurality of information carrying cards, comprising forming a core layer for the plurality of information carrying cards according to claim 7 .

20. A method of claim 19 further comprising
laminating a printable thermoplastic film on one side of the core layer, after the crosslinkable polymer composition is cured to form a crosslinked polymer composition;
laminating a transparent thermoplastic film on the printable thermoplastic film on one side of the core layer; and
cutting the core layer for the plurality of information carrying cards into individual information carrying cards.

Assignees

• X Card Holdings Llc

Inventors

• Cox Mark A

Classifications

• Y10T428/1352

  Polymer or resin containing [i.e., natural or synthetic] · CPC title

• F21V33/0004

  Personal or domestic articles · CPC title

• G06K19/07724

  the record carrier being at least partially made by a molding process (molding in general B29C45/14) · CPC title

• Y10T428/1355

  Elemental metal containing [e.g., substrate, foil, film, coating, etc.] · CPC title

• H05K1/182

  associated with components mounted in printed circuit boards [PCB], e.g. insert-mounted components [IMC] · CPC title