US 11,884,051 B2
Methods of making a core layer for an information carrying card, and resulting products
Mark A. Cox, West Chester, PA (US)
Assigned to X-Card Holdings, LLC, West Chester, PA (US)
Filed by X-Card Holdings, LLC, West Chester, PA (US)
Filed on Dec. 30, 2020, as Appl. No. 17/137,579.
Application 17/137,579 is a continuation of application No. 15/510,815, granted, now 10,906,287, previously published as PCT/US2014/021553, filed on Mar. 7, 2014.
Claims priority of provisional application 61/794,409, filed on Mar. 15, 2013.
Prior Publication US 2021/0114365 A1, Apr. 22, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 37/12 (2006.01); B32B 27/32 (2006.01); B32B 3/08 (2006.01); B32B 7/06 (2019.01); B32B 27/36 (2006.01); B32B 27/10 (2006.01); B32B 27/38 (2006.01); B32B 15/08 (2006.01); B32B 3/30 (2006.01); B32B 3/04 (2006.01); B32B 27/34 (2006.01); B32B 9/04 (2006.01); B32B 27/28 (2006.01); B32B 29/00 (2006.01); B32B 15/20 (2006.01); B32B 7/12 (2006.01); B32B 3/26 (2006.01); B32B 9/00 (2006.01); B32B 27/30 (2006.01); B32B 27/08 (2006.01); B32B 37/10 (2006.01); G06K 19/077 (2006.01); B32B 37/06 (2006.01); B32B 37/00 (2006.01); B32B 37/26 (2006.01); B32B 38/00 (2006.01)
CPC B32B 37/12 (2013.01) [B32B 3/04 (2013.01); B32B 3/08 (2013.01); B32B 3/263 (2013.01); B32B 3/30 (2013.01); B32B 7/06 (2013.01); B32B 7/12 (2013.01); B32B 9/005 (2013.01); B32B 9/045 (2013.01); B32B 15/08 (2013.01); B32B 15/20 (2013.01); B32B 27/08 (2013.01); B32B 27/10 (2013.01); B32B 27/281 (2013.01); B32B 27/283 (2013.01); B32B 27/302 (2013.01); B32B 27/304 (2013.01); B32B 27/32 (2013.01); B32B 27/322 (2013.01); B32B 27/34 (2013.01); B32B 27/36 (2013.01); B32B 27/365 (2013.01); B32B 27/38 (2013.01); B32B 29/005 (2013.01); B32B 37/06 (2013.01); B32B 37/10 (2013.01); B32B 37/1018 (2013.01); G06K 19/07722 (2013.01); B32B 37/0046 (2013.01); B32B 37/1054 (2013.01); B32B 37/26 (2013.01); B32B 2038/0076 (2013.01); B32B 2250/40 (2013.01); B32B 2250/44 (2013.01); B32B 2255/00 (2013.01); B32B 2255/06 (2013.01); B32B 2255/10 (2013.01); B32B 2255/26 (2013.01); B32B 2305/342 (2013.01); B32B 2305/72 (2013.01); B32B 2307/204 (2013.01); B32B 2307/412 (2013.01); B32B 2307/546 (2013.01); B32B 2307/724 (2013.01); B32B 2307/748 (2013.01); B32B 2307/75 (2013.01); B32B 2309/105 (2013.01); B32B 2425/00 (2013.01); B32B 2429/00 (2013.01); Y10T 156/1089 (2015.01)] 20 Claims
OG exemplary drawing
 
1. A method for forming a core layer of a plurality of information carrying card, comprising:
forming a first thermoplastic layer being monolithic and defining a plurality of cavities, each cavity having a continuous surface profile defined by and being inside the first thermoplastic layer, the continuous surface profile including a bottom wall surface and a sidewall surface in a same surface profile, the first thermoplastic layer comprising at least one thermoplastic material;
disposing a plurality of inlay layers onto the first thermoplastic layer, wherein at least one portion of each inlay layer is disposed into each respective cavity of the plurality of cavities;
dispensing a crosslinkable polymer composition into each of the plurality of cavities so as to contact one portion of each inlay layer to form a sandwich structure comprising the first thermoplastic layer, each inlay layer and the crosslinkable polymer composition; and
curing the crosslinkable polymer composition under pressure and heat to form a crosslinked polymer composition, wherein curing the crosslinkable polymer composition under the pressure comprises pressing the sandwich structure between two metal plates spaced by a metal frame having a controlled thickness.