US 11,989,611 B2
Manufacturing method of a radio-frequency smart card with a metal inlay assembly
Yeow Chun Ricky Choo, Singapore (SG); Antoine Bajolle, Singapore (SG); Nancy Cornel Alegado, Singapore (SG); and Jason Reyes Bayla, North Wales, PA (US)
Assigned to THALES DIS FRANCE SAS, Meudon (FR)
Appl. No. 17/928,301
Filed by THALES DIS FRANCE SAS, Meudon (FR)
PCT Filed Jun. 9, 2021, PCT No. PCT/EP2021/065467
§ 371(c)(1), (2) Date Nov. 29, 2022,
PCT Pub. No. WO2021/250100, PCT Pub. Date Dec. 16, 2021.
Claims priority of application No. 20315300 (EP), filed on Jun. 9, 2020.
Prior Publication US 2023/0206021 A1, Jun. 29, 2023
Int. Cl. G06K 19/06 (2006.01); G06K 19/077 (2006.01)
CPC G06K 19/07775 (2013.01) [G06K 19/07722 (2013.01); G06K 19/0776 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A Manufacturing method of a radio-frequency (1A, 1B) smart card with a metal inlay (4), said method including the following steps:
forming a card body (1A, 1B, 11) including said metal inlay (4) in the form of a metal plate equipped with a cavity (22);
arranging at least a radiofrequency transponder (5c) antenna inside this cavity (22);
arranging an external metal element (4e) around said metal plate, arranged as internal metal plate (4i), for forming the metal inlay (4), said external metal element being visible on the edge (14) of the card (11), wherein the external metal element (4e) comprises an external metal plate (4i) arranged around said internal metal plate (4i),
assembling of a first thermosetting adhesive film (3) on a first side of a perforated core sheet (8) setting out perforation areas (P) for component locations (4);
fixing the metal plate assembly (4) and the radiofrequency transponder antenna inlay (46) to the first adhesive (3) film through insertion in the perforation areas (P);
providing a second thermosetting adhesive film (2) identical or similar to the first one on a second side opposite to a first side of said perforated core sheet (8);
thermal lamination of said core sheet (4, 8) with first and second thermosetting adhesive films (2, 3) to form a composite inlay; and
extracting each card (11) from the multiplayer card structure.