Patent ID: 8324021
Filing Date: 2012-12-04
Classification: B29C,G06K,Y10T

Abstract:
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: (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.