Patent ID: 7823792

Claim:
A method of manufacturing a plurality of contactless smart cards, the method comprising: providing a first contact layer and a second contact layer, the first contact layer comprising a front surface and a back surface, and the second contact layer comprising a front surface and a back surface; overlaying the first contact layer with a first layer of adhesive along the front surface and with a second layer of adhesive along the back surface, such that, the first contact layer is disposed between the first layer of adhesive and the second layer of adhesive overlaid on the first contact layer, at least one of the first adhesive layer and the second adhesive layer overlaid on the first contact layer being adapted to have human-readable indicia provided thereon; overlaying the second contact layer with a first layer of adhesive along the front surface and with a second layer of adhesive along the back surface, such that, the second contact layer is disposed between the first layer of adhesive and the second layer of adhesive overlaid on the second contact layer, at least one of the first adhesive layer and the second adhesive layer overlaid on the second contact layer being adapted to have human-readable indicia provided thereon; providing a carrier having a top surface and a bottom surface, the carrier comprising a plurality of antennas and electronic circuitry; wherein the carrier layer includes a permeable scrim or mesh, and wherein applying at least one of heat and pressure includes applying at least one of heat and pressure sufficient, such that, at least a portion of at least one of the first contact layer and the second contact layer migrates into or through the permeable carrier layer core; sandwiching the carrier between the second adhesive layers of the first contact layer and the second adhesive layers of the second contact layer; providing human-readable indicia on at least one of the front surface of at least one of the first and second contact layers, wherein the indicia comprises personalized information corresponding, respectively, to a prospective card bearer, for each of a plurality of different cards; laminating each of the first contact layer and the second contact layer on the front surface of each respective contact layer over the respective first layer of adhesive to form two laminated surfaces; applying at least one of pressure and heat combining the laminated surfaces, the first contact layer, the second contact layer and the carrier and forming a multi-layer structure; and cutting the multi-layer structure to yield a plurality of contactless smart cards, wherein each of the plurality of contactless smart cards includes an antenna and electronic circuitry and human-readable indicia.