US 12,220,897 B2
Core layer for information carrying card, resulting information carrying card, and methods of making the same
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 Oct. 20, 2022, as Appl. No. 17/970,155.
Prior Publication US 2024/0131826 A1, Apr. 25, 2024
Prior Publication US 2024/0227368 A9, Jul. 11, 2024
Int. Cl. B32B 3/24 (2006.01); B32B 3/18 (2006.01); B32B 3/26 (2006.01); B32B 7/12 (2006.01); B32B 27/08 (2006.01); B32B 27/30 (2006.01)
CPC B32B 27/08 (2013.01) [B32B 3/18 (2013.01); B32B 3/266 (2013.01); B32B 7/12 (2013.01); B32B 27/304 (2013.01); B32B 2307/41 (2013.01); B32B 2307/412 (2013.01); B32B 2307/414 (2013.01); B32B 2307/748 (2013.01); B32B 2307/75 (2013.01); B32B 2425/00 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A core layer for a plurality of information carrying cards comprising:
a first thermoplastic layer, the first thermoplastic layer comprising a thermoplastic material;
a plurality of inlay layers, wherein each of the plurality of inlay layers comprises at least one electronic component;
a second thermoplastic layer disposed over the first thermoplastic layer, wherein the second thermoplastic layer comprises a second thermoplastic material and defines a plurality of through-holes therein;
a crosslinked polymer composition including a first portion, a second portion, and a third portion,
wherein the first portion of the crosslinked polymer composition is a layer disposed between the first thermoplastic layer and the second thermoplastic layer, the second portion of the crosslinked polymer composition is disposed inside each of the plurality of through-holes and one respective inlay layer is disposed inside the second portion of the crosslinked polymer composition so as to be freely movable inside each respective through-hole before the crosslinked polymer composition is crosslinked under a pressure and a temperature, and the third portion of the crosslinked polymer composition is a layer disposed over each respective inlay layer and on the second thermoplastic layer,
wherein the respective inlay layer is centered inside the second portion of the crosslinked polymer composition inside each of the plurality of through-holes with respect to a thickness of the second thermoplastic layer and/or edges of a respective through-hole.