Card comprising at least one electronic element and method of manufacture of such a card

Claim 1

A method of manufacture of an electronic information bearing plastic card to be carried on a person of a user comprising at least one coil electrically connected to an electronic element including the following steps: IA) bringing onto a work surface a first outer layer formed from a solid plastic material; IB) placing said coil and said electronic element onto said first outer layer in a form in which said coil and said electronic element are not commonly encased in a carrier element; IC) applying a binding material onto said coil, said electronic element and said first outer layer in a liquid form; ID) bringing a second outer layer formed from a solid plastic material onto said liquid binding material and facing said first outer layer; such steps being succeeded by the following step: IE) applying pressure on said first and second outer layers until such first and second outer layers are located at a predetermined distance relative to one another, said binding material being thereby caused to spread out and fill an intermediate region between said first and second outer layers by eliminating substantially all air bubbles and air cavities in this intermediate region so as to form a completely filled intermediate layer having a predetermined thickness and having at least one dimension equal to a corresponding exterior dimension of the resulting card in a direction in a general plane of the resulting card, said first and second outer layers having respectively first and second internal surfaces defined respectively by the entire surfaces of these first and second outer layers facing one another, at least a major portion of said first and second internal surfaces being covered over by said binding material so as to assure cohesion of said first and second outer layers with said intermediate layer, said coil and said electronic element each being embedded in said binding material forming said intermediate layer.

Claim 2

A method of manufacture of an electronic information bearing plastic card to be carried on a person of a user comprising at least one coil electrically connected to an electronic element including the following steps: IA) bringing onto a work surface a first outer layer formed from a solid plastic material; IB) placing said coil and said electronic element onto said first outer layer in a form in which said coil and said electronic element are not commonly encased in a carrier element; IC) applying a binding material onto said coil, said electronic element and said first outer layer in a liquid form; ID) bringing a second outer layer formed from a solid plastic material onto said liquid binding material and facing said first outer layer; such steps being succeeded by the following step: IE) applying pressure on said first and second outer layers until such first and second outer layers are located at a predetermined distance relative to one another, said binding material being thereby caused to spread out and fill an intermediate region between said first and second outer layers by eliminating substantially all air bubbles and air cavities in this intermediate region so as to form a completely filled intermediate layer having a predetermined thickness and having at least one dimension equal to a corresponding exterior dimension of the resulting card in a direction in a general plane of the resulting card, said first and second outer layers having respectively first and second internal surfaces defined respectively by the entire surfaces of these first and second outer layers facing one another, at least a major portion of said first and second internal surfaces being covered over by said binding material so as to assure cohesion of said first and second outer layers with said intermediate layer, said coil and said electronic element each being embedded in said binding material forming said intermediate layer.

Claim 16

A method of manufacture of an electronic information bearing plastic card to be carried on a person of a user comprising at least one electronic element including the following steps: IA) bringing onto a work surface a first outer layer formed from a solid material; IF) Applying a positioning structure defining an internal zone and exhibiting a relief on both its upper and lower faces; IB) placing said electronic element onto said first outer layer within said internal zone; IC) bringing a binding material onto said first outer layer; ID) bringing a second outer layer formed from a solid material onto said binding material and facing said first outer layer; such steps being succeeded by the following step: IE) applying pressure on said first and second outer layers until such first and second outer layers are located at a predetermined distance relative to one another, said binding material then forming between said first and second outer layers an intermediate layer having a predetermined thickness and having at least one dimension equal to a corresponding exterior dimension of the resulting card in a direction in a general plane of the resulting card.

Claim 17

A method of manufacture of an electronic information bearing plastic card to be carried on a person of a user comprising at least one electronic element including the following steps: IA) bringing onto a work surface a first outer layer formed from a solid material; IF) Applying a positioning structure defining an internal zone and exhibiting a relief on both its upper and lower faces; IB) placing said electronic element onto said first outer layer within said internal zone; IC) bringing a binding material onto said first outer layer; ID) bringing a second outer layer formed from a solid material onto said binding material and facing said first outer layer; such steps being succeeded by the following step: IE) applying pressure on said first and second outer layers until such first and second outer layers are located at a predetermined distance relative to one another, said binding material then forming between said first and second outer layers an intermediate layer having a predetermined thickness and having at least one dimension equal to a corresponding exterior dimension of the resulting card in a direction in a general plane of the resulting card.