Smart card with an inlay layer encapsulating a carbon fiber plug.

Abstract

The invention relates to a smart card having an inlay layer, the inlay layer comprising a card body (100), the card body defining at least one main cavity within the card body, each main cavity of the at least one main cavity having a continuous surface defined by an inner surface of the card body, a carbon fiber plugging portion (110), the carbon fiber plugging portion being housed inside the at least one main cavity, an antenna (120), the antenna being housed inside the at least one main cavity, and a monomer or polymer layer disposed on an outer surface of the inlay layer, the monomer or polymer layer being in contact with an outer surface of the carbon fiber plugging portion. Figure 1A

Description

Title of the invention: Smart card with an inlay layer encapsulating a carbon fiber sealing portion

[0001] This disclosure relates to the design and structure of smart cards comprising a carbon fibre material.

[0002] It is necessary to use smart cards comprising carbon fibers in the luxury banking sector and other industries where it is advantageous to have a solid, durable and corrosion-resistant card, comprising incorporated electronic components used for interaction with a card reader.

[0003] Carbon fibers exhibit strong radio frequency blocking, effectively nullifying the contactless communication capabilities of a smart card. Carbon fibers are also difficult to cut and are incompatible with the machines used in the card manufacturing industry. Carbon fiber particles are sharp and can injure smart card users. Therefore, it is necessary to incorporate carbon fibers into a smart card while maintaining the size, manufacturability, and functionality of a conventional smart card and ensuring the safety of smart card users.

[0004] The above "background" description is provided for the purpose of presenting the general context of the disclosure. The inventors' work, to the extent described in this background section, and aspects of the description that cannot otherwise be considered prior art as of the filing date, are not either expressly or implicitly admitted as prior art with respect to this disclosure.

[0005] The present invention aims to overcome these drawbacks.

[0006] The preceding paragraphs are presented by way of general introduction and are not intended to limit the scope of the following claims. The embodiments described, together with other advantages, will be better understood by reference to the detailed description below, considered in conjunction with the accompanying drawings.

[0007] The disclosure proposes in particular an inlay layer of a smart card, comprising a card body, the card body defining at least one main cavity, each main cavity of the at least one main cavity having a continuous surface defined by an interior surface of the card body; a carbon fiber plugging portion, the carbon fiber plugging portion being housed inside the at least one main cavity; and an antenna, the antenna being housed inside the at least one main cavity.

[0008] This inlay layer may also include the following optional features, considered individually or in combination where technically feasible: - the card body is made of a metal or a polymer; - the continuous surface of at least one main cavity and the edges of the card body are spaced at least 0.5 mm apart; - the continuous surface of at least one main cavity is discontinuous with an edge of the card body; - the carbon fiber sealing part defines an additional cavity in the carbon fiber sealing part; - the antenna is housed completely or partially by the additional cavity in the carbon fiber sealing part; - the additional cavity in the carbon fiber sealing part extends through the upper and lower outer surfaces of the carbon fiber sealing part; - at least one main cavity is a first main cavity and a second main cavity, the first main cavity and the second main cavity being disjoint, and the carbon fiber sealing part being housed inside the first main cavity and the antenna being housed inside the second main cavity.

[0009] The disclosure also proposes a smart card, comprising an inlay layer, the inlay layer comprising a card body, the card body defining at least one main cavity in the card body, each main cavity of the at least one main cavity having a continuous surface defined by an interior surface of the card body; a carbon fiber plugging portion, the carbon fiber plugging portion being housed inside the at least one main cavity; and an antenna, the antenna being housed inside the at least one main cavity; and a monomer or polymer layer disposed on an exterior surface of the inlay layer, the monomer or polymer layer being in contact with an exterior surface of the carbon fiber plugging portion.

[0010] The inlay layer of this smart card can be adapted according to each of the embodiment possibilities defined above.

[0011] In one embodiment, this disclosure relates to a method for manufacturing a smart card inlay, the method comprising forming a card body from a metal or polymer; forming at least one main cavity in the card body, each main cavity having a continuous surface defined by an interior surface of the card body; and forming a carbon fiber plugging portion from fibers of carbon; the deposition of the carbon fibre plugging portion in at least one main cavity in the card body; and the deposition of an antenna in at least one main cavity in the card body.

[0012] This method for manufacturing a smart card inlay may also include the following optional features, considered individually or in combination where technically feasible: - the process further includes the formation of an additional cavity in the carbon fibre sealing part, the antenna being housed partially or completely in the additional cavity in the carbon fibre sealing part; - at least one main cavity is a first main cavity and a second main cavity, the first main cavity and the second main cavity being disjoint, and the carbon fiber plugging part being deposited in the first main cavity and the antenna being deposited in the second main cavity.

[0013] The manufacturing process for a smart card inlay can be adapted according to each of the embodiment possibilities defined previously for the inlay layer.

[0014] A more complete appreciation of the disclosure and many of its related benefits will be readily obtained when it is better understood by reference to the detailed description below when considered in conjunction with the corresponding figures, in which:

[0015] [Fig.1A] is an assembled card body, according to an embodiment illustrative of the present disclosure;

[0016] [Fig. IB] is a carbon fibre plugging part, according to an embodiment illustrative of the present disclosure;

[0017] [Fig.2A] is an assembled card body, according to an embodiment illustrative of the present disclosure;

[0018] [Fig.2B] is a carbon fibre plugging part, according to an embodiment illustrative of the present disclosure;

[0019] [Fig.3A] is an assembled card body, according to an embodiment illustrative of the present disclosure;

[0020] [Fig.3B] is a carbon fibre plugging part, according to an embodiment illustrative of the present disclosure;

[0021] [Fig.4] is a card body, according to an illustrative embodiment of the present disclosure ;

[0022] [Fig.5] is a card body sheet, according to an illustrative embodiment of the present disclosure;

[0023] [Fig. A] is an exploded view of a smart card, according to an embodiment illustrative of the present disclosure;

[0024] [Fig.6B] is an isometric exploded view of a smart card, according to an embodiment illustrative of the present disclosure;

[0025] [Fig.7] is an exploded view of an inset, according to an illustrative embodiment of this disclosure;

[0026] [Fig.8] is a method for assembling an inlay, according to an embodiment illustrative of this disclosure;

[0027] [Fig.9] is an exploded view of a sheet of smart cards, according to a mode of illustrative representation of this disclosure; and

[0028] [Fig. 10] is a method for assembling a smart card, according to an embodiment illustrative of the present disclosure.

[0029] The terms "a" or "an," as used herein, are defined as one or more. The term "plurality," as used herein, is defined as two or more. The term "another," as used herein, is defined as at least one or more. The terms "comprising" and / or "having," as used herein, are defined as including (i.e., open language). Reference throughout this document to "an embodiment," "certain embodiments," "an embodiment," "an implementation," "an example," or similar terms means that a particular element, structure, or feature described in association with the embodiment is included in at least one embodiment of this disclosure. Thus, occurrences of such expressions in various places throughout this specification do not necessarily all refer to the same embodiment.Furthermore, particular elements, structures or features can be combined in any appropriate way in one or more embodiments without limitation.

[0030] Smart cards can be used to digitally provide data to be read by a device. Examples of smart cards include, but are not limited to, credit / debit cards, identification cards, transit cards, calling cards, and access cards. The information provided on the card can be stored or accessed via an integrated circuit (IC) embedded in the card. The IC may include a microcontroller or similar processor and memory storage. The IC can be configured for data storage and retrieval, encryption, authentication, and other functions necessary for data transfer and authentication. The device interacting with the card can be a reader equipped to scan or read a smart card and initiate a data transfer with the smart card.The scanning or reading process may involve scanning a magnetic stripe or contacting a chip embedded in the card body. Contactless readers are becoming increasingly popular. Smart cards may have an antenna embedded in the card body to enable... contactless data transfer between the chip's integrated circuit and the reader. Contactless data transfer can be initiated by inductive coupling, such as in near-field communication (NFC) protocols.

[0031] Smart cards can be composed of layers of material to enclose an integrated circuit (IC) and additional electronic components for data storage and transfer. In addition, smart cards typically include a patterned or decorative layer for visual and informational purposes. Numerous considerations exist in the design and manufacture of smart cards. For example, durability, security, performance, compliance with institutional standards, cost, material usage, ease of manufacture, appearance, and tactile feel are all factors that affect how smart cards are produced. The desired properties of a smart card may depend on the card's intended use. For example, cards that are carried and used regularly, such as credit cards, should be durable and resistant to corrosion or breakage while still providing the necessary functionality.The cards are also designed and manufactured to meet International Organization for Standardization (ISO) standards regarding card dimensions and transmission protocols for relevant industries.

[0032] In certain industries, smart cards incorporating carbon fibers are required while maintaining the card's functionality and desired characteristics, such as durability, machinability, user security, and compliance with standards. For example, credit cards (or similar payment cards) incorporating carbon fibers are required in the luxury banking sector due to their aesthetic appeal. Credit cards incorporating carbon fibers may have different visual and tactile properties that distinguish them from conventional cards; for example, a smart card incorporating carbon fibers may be lighter than conventional smart cards. However, carbon fibers have unfavorable properties, such as shielding against radio frequencies and sharp particles.Machining smart cards containing carbon fibers, which are not typically used in mass production, can also be problematic. Therefore, it is necessary to design and manufacture smart cards incorporating carbon fibers that can be easily produced, are as efficient for contactless data transfer with readers, and are as safe for the user handling these smart cards as conventional smart cards.

[0033] In one embodiment, the present disclosure relates to a smart card having a carbon fiber sealing portion incorporated into the body of The card and an associated manufacturing process. The card body, including the plugging portion, can form the core of the smart card and can be encapsulated by resin or other substrates. The card body can also include electronic components, including an antenna, an integrated circuit, and / or other circuit elements used for card scanning functionality. The antenna can be incorporated into the card body along with the carbon fiber plugging portion in such a way as not to impede card functionality or expose the electronic components to points of failure. In some implementations, the carbon fiber plugging portion and the antenna can be incorporated into the card body and allow for contactless reading in close proximity to the card body.A smart card may include one or more circuit components, including, but not limited to, an antenna, a microprocessor, data storage, or other integrated circuit chips. In one embodiment, the antenna may be a primary circuit component enabling data transfer between a smart card and a reader. The antenna may be incorporated along with the carbon fiber plug within the card body. Additional circuit components may be incorporated into the card body throughout the manufacturing process, including after a card has been assembled and separated from a sheet of cards. These additional circuit components may be incorporated at various locations throughout the card body. The placement of the carbon fiber plug and the antenna does not affect the placement of the additional circuit components within the smart card.Alternatively, the antenna may incorporate the circuit component(s), including a microprocessor, data storage, or other integrated circuit elements, on a single integrated circuit chip, which may be embedded in the card. The antenna description throughout this disclosure may refer to a separate antenna component and / or an antenna that is integrated with, or combined with, additional smart card circuit elements known to those skilled in the art. A wide variety of configurations and geometries of the card body, carbon fiber plug, and circuit elements may be compatible with this disclosure and will be disclosed herein as non-limiting embodiments. The card body surrounding the carbon fiber plug may protect the carbon fiber plug from exposure at the edges of the smart card and thus from tampering..

[0034] According to some embodiments, the card body may be made of stainless steel, another machinable metal, or a polymer, for example polyvinyl chloride (commonly referred to by the acronym PVC) or polycarbonates (commonly referred to by the acronym PC). The carbon fiber sealing portion is made of carbon fibers, for example the part The carbon fiber plug is solid and consists of pre-laminated carbon fibers impregnated with a resin. For illustrative purposes, smart cards incorporating a carbon fiber plug and a card body made of a metal or polymer will be described here. Various families of stainless steel and similar alloys, or polymers, can be used for the card body. By selecting metals or polymers for the card body, the smart card can achieve the desired weight while maintaining or improving machinability. A metal card body is, by nature, heavier than a polymer card body. Stainless steel or a polymer can be used in the card body because of its corrosion resistance, rigidity, low-frequency radio frequency permeability, machinability, and industrial availability.

[0035] Advantageously, the card body can be made of PVC in different colors to obtain smart cards comprising carbon fibers and colored edges.

[0036] Advantageously, the card body can be made of metal to obtain a more rigid and robust smart card including carbon fibers.

[0037] In some embodiments, the carbon fiber plugging portion may be a sheet or plate of carbon fibers incorporated into a cavity, called the main cavity, in the card body. Different carbon fiber weaves may be used to meet design requirements, for example, a twill weave, a satin weave, or a patterned weave. In one embodiment, the carbon fiber plugging portion may be approximately rectangular in shape. The main cavity may be sized to the shape and dimensions of the carbon fiber plugging portion to prevent any movement of the carbon fibers within the main cavity. The carbon fiber plugging portion may be located anywhere within the card body.As described previously, it can be advantageous to completely encapsulate the carbon fiber plug within the card body so that the edges of the carbon fiber plug are not exposed at the edges of the card body. This allows the main cavity within the card body to be entirely contained and not adjacent to the card body edges. The edges of a smart card are vulnerable to wear from daily handling and contact with other surfaces or materials. Enclosing the carbon fiber plug completely within the card body can protect the plug while preventing smart card users from coming into contact with potentially sharp carbon fiber particles that could cause injury. Furthermore, the card body can still be manufactured to the typical shape and dimensions of a smart card. The smart card (for example, a rectangle) is used as the first step in assembling the card body. Furthermore, incorporating the carbon fiber core into the card body can lead to a more durable smart card, since carbon fibers pre-laminated with resin have good flexural strength but are also brittle when a stress limit is exceeded. The stress limit of the carbon fibers may be lower than the mechanical stress limit defined by standards for smart cards, for example, in sections 8.1 and 8.14 of ISO / IEC 7810, Fourth Edition, 2019-12. The card body, made of metal or polymer, reinforces the smart card structure.In some embodiments, the shape of the carbon fiber plugging portion may depend on the shape and positioning of the antenna and other circuit elements within the board body, as will be described in more detail here. In some embodiments, the main cavity may be a through-hole inside the board body.

[0038] Figure IA illustrates a carbon fiber plug 110 and an antenna 120 incorporated into a card body 100, according to an embodiment of this disclosure. The card body 100 can form the body of the smart card. The card body 100 can be approximately rectangular with rounded corners. Illustrative card and component dimensions are shown here as non-limiting, illustrative embodiments. In one embodiment, the card body 100 can be approximately 85.928 mm wide and 54.331 mm high. In one embodiment, the sealing part 110 is made of carbon fibers and the card body 100 can be made of a metal, for example stainless steel or another metal that can be machined, or of a polymer, for example polyvinyl chloride (commonly referred to by the acronym PVC) or polycarbonates (commonly referred to by the acronym PC).In one embodiment, the antenna 120 may include any circuit elements used for smart card functionality, including, but not limited to, processing circuit elements and memory. A main cavity may be formed in the card body 100 to completely contain and encapsulate the carbon fiber plugging portion 110. Thus, the card body defines a main cavity having a continuous surface defined by an inner surface of the card body. In one embodiment, the main cavity may be completely contained within the card body 100 such that the continuous surface of the main cavity is discontinuous with the edges of the card body 100. The carbon fiber plugging portion 110 is not in contact with the edges of the card body 100 when placed in the main cavity, which is completely contained within the card body 100.Advantageously, the continuous surface of the main cavity. and the edges of the card body are spaced at least 0.5 mm apart. The distances between the continuous surface of the main cavity and the edges of the card body are indicated by A, B, C, and D in [Fig. 1A]. In one embodiment, the continuous surface of the main cavity may be continuous with respect to one or more edges of the card body 100 such that the carbon fiber plugging portion 110 is in contact with one or more edges of the card body 100 when placed in the main cavity. In this embodiment, the card body protects the plugging portion while limiting the exposure of the carbon fibers on at least one edge of the smart card. In some embodiments, the main cavity may include a space for the antenna 120. The carbon fiber plugging portion 110 may occupy any part of the area of ​​the card body 100.In one embodiment, the main cavity may be formed in a first outer surface (e.g., the upper surface) of the card body such that the carbon fiber plugging portion 110 can be exposed at the upper surface of the card body 100 when the carbon fiber plugging portion 110 is placed in the main cavity. In some embodiments, the main cavity may be a through hole cut through the first outer surface (e.g., the upper surface) and the second opposite outer surface (e.g., the lower surface) of the card body 100 such that the carbon fiber plugging portion 110 can be exposed at both the upper and lower surfaces of the card body 100 when the carbon fiber plugging portion 110 is placed in the main cavity.In some implementations, the design of the carbon fiber plugging portion of [Fig.1A] can lead to a regular distribution of the carbon fiber weight over the entire board.

[0039] In one embodiment, the carbon fiber sealing portion 110 can completely encapsulate and contain the antenna 120, as shown in [Fig. 1A]. The carbon fiber sealing portion 110 may include an antenna cutout, also called an additional cavity, the antenna 120 being able to be inserted into the antenna cutout. The antenna 120 can be surrounded by the carbon fibers of the carbon fiber plugging portion 110. An edge of the antenna 120 can be flush with an edge of the carbon fiber plugging portion 110, as illustrated in [Fig. 1A], so that the antenna 120 is contained within the carbon fiber plugging portion 110. In one embodiment, the carbon fiber plugging portion 110 can surround the antenna 120 and extend beyond the antenna 120. The antenna 120 can be positioned and oriented in any direction within the carbon fibers 110.According to some embodiments, the antenna 120 can be placed in the card body 100 so that . The antenna is exposed on both the top and bottom surfaces of the card body. Exposing the 120 antenna on both sides of the carbon fiber card body ensures improved reception for wireless data transmission.

[0040] [Fig. IB] is an illustration of the carbon fiber plugging portion 110, according to an embodiment of this disclosure. The carbon fiber plugging portion 110 of [Fig. IB] can be used in the card body design of [Fig. IA]. According to the illustrated example, the carbon fiber plugging portion 110 can be approximately rectangular with rounded corners. In one example, the carbon fiber plugging portion 110 can be approximately 74.656 mm wide and approximately 47.831 mm high. The radius of the rounded edges can be approximately 2.750 mm. Variations in the shapes and geometries of the carbon fiber plugging portion 110 are compatible with this disclosure. In some embodiments, the design of [Fig.[Fig. 1A] can maximize the amount of carbon fiber used in the board since the carbon fiber plugging portion 110 can occupy the majority of the board body's surface area. In one embodiment, the carbon fiber plugging portion 110 may include an antenna cutout 115, also called an additional cavity, for antenna placement. The antenna can be completely housed by the additional cavity within the carbon fiber plugging portion. In other words, the carbon fiber plugging portion 110 of [Fig. 1A] and [Fig. 1B] can completely encapsulate the antenna. Thus, the antenna cutout 115 can be shaped like the antenna and can be machined to the antenna's dimensions. For example, the antenna cutout 115 may include a rounded portion with a radius of approximately 12.921 mm and a rectangular portion, depending on the antenna's shape.The cutout can be symmetrical or asymmetrical depending on the shape of the antenna. For example, one edge of the cutout may extend beyond an opposite edge. The antenna may be centered within the carbon fiber plugging portion 110 or positioned anywhere within it. In one embodiment, an edge of the antenna cutout 115 or a portion of its perimeter may be aligned with an edge of the carbon fiber plugging portion 110, as illustrated in [Fig. 1B]. In one embodiment, the carbon fiber plugging portion 110 may be in contact with the portion of the antenna 120 that is encapsulated by the carbon fiber plugging portion.In one embodiment, the entire antenna can be enclosed within the carbon fiber sealing portion, and the carbon fiber sealing portion can be a closed rectangle. The cutout for... The antenna 115 can be cut through the carbon fiber plugging portion 110 such that the upper and lower surfaces of the antenna are exposed when the antenna is placed in the antenna cutout 115. In one embodiment, the thickness of the carbon fiber plugging portion can be approximately 0.200 mm to 0.840 mm thick, for example, 0.305 mm thick. In another embodiment, the card body can be approximately 0.200 mm to 0.840 mm thick, for example, approximately 0.305 mm thick. Preferably, the thickness of the card body is equal to the thickness of the carbon fiber plugging portion.

[0041] Fig. 1 A is an illustration of what can also be defined as: - a card body 100, the card body defining a main cavity, the main cavity having a continuous surface defined by an interior surface of the card body, - a carbon fiber plugging part 110, the carbon fiber plugging part being housed inside the main cavity, - an antenna 120, the antenna being housed inside the main cavity, the carbon fiber plugging part defining an additional cavity in the carbon fiber plugging part and the antenna being housed completely by the additional cavity in the carbon fiber plugging part.

[0042] Figure 2A illustrates a carbon fiber plug 210 and an antenna 220 incorporated into a card body 200, according to an embodiment of this disclosure. The card body 200 can form the body of the smart card. The card body 200 can be approximately rectangular with rounded corners. Illustrative card and component dimensions are shown here as non-limiting, illustrative embodiments. In one embodiment, the card body 200 can be approximately 85.928 mm wide and 54.331 mm high.In one embodiment, the carbon fiber sealing portion 210 is composed of the carbon fiber sealing portion, and the card body 200 may be composed of a metal, for example, stainless steel or another machinable metal, or a polymer, for example, polyvinyl chloride (commonly referred to as PVC) or polycarbonates (commonly referred to as PC). In one embodiment, the antenna 220 may include any circuit elements used for smart card functionality, including, but not limited to, processing circuit elements and memory. A main cavity may be formed in the card body 200 to completely contain and encapsulate the carbon fiber sealing portion 210. Thus, the card body defines a main cavity having a continuous surface defined by an inner surface of the card body. In one embodiment. In this embodiment, the main cavity can be completely contained within the card body 200 such that the continuous surface of the main cavity is discontinuous with the edges of the card body 200. The carbon fiber plugging portion 210 is not in contact with the edges of the card body 200 when placed in the main cavity, which is completely contained within the card body 200. Advantageously, the continuous surface of the main cavity and the edges of the card body are separated by a minimum of 0.5 mm. The distances between the continuous surface of the main cavity and the edges of the card body are indicated by A, B, C, and D in [Fig. 2A].In one embodiment, the continuous surface of the main cavity may be continuous with respect to one or more edges of the card body 200 such that the carbon fiber plugging portion 210 is in contact with one or more edges of the card body 200 when placed in the main cavity. In this embodiment, the card body protects the plugging portion while limiting the exposure of the carbon fibers on at least one edge of the smart card. In some embodiments, the main cavity may include a space for the antenna 120. The carbon fiber plugging portion 210 may occupy any part of the area of ​​the card body 200.In one embodiment, the main cavity may be formed in a first outer surface (for example, the upper surface) of the card body such that the carbon fiber plugging portion 210 can be exposed at the upper surface of the card body 200 when the carbon fiber plugging portion 210 is placed in the main cavity. In some embodiments, the main cavity may be a cutout through the first surface (for example, the upper surface) of the card body 200 and the second opposite outer surface (for example, the lower surface) of the card body 200 such that the carbon fiber plugging portion 210 can be exposed at both the upper and lower surfaces of the card body when the carbon fiber plugging portion is placed in the main cavity.According to some embodiments, the antenna 220 can be placed in the card body 200 so that the antenna is exposed at the top and bottom surfaces of the card body. Exposure of the antenna 220 on both sides of the card body can ensure improved reception for wireless data transmission.

[0043] In one embodiment, the carbon fiber plugging portion 210 can partially encapsulate the antenna 220 as shown in [Fig. 2A]. The carbon fiber plugging portion 210 may have an antenna cutout, also called an additional cavity, a portion of the antenna 220 being able to fit into the cutout of the carbon fiber plugging portion 210. A portion of the antenna 220 may be surrounded by the carbon fiber plugging portion 210. In one embodiment, the carbon fiber plugging portion 210 can be in contact with the antenna portion 220, which is partially encapsulated by the carbon fiber plugging portion. The remaining portion of the antenna can extend beyond the carbon fiber plugging portion 210 and be incorporated directly into the card body 200. The antenna 220 is partially constrained by the carbon fiber plugging portion 210 and partially constrained by the card body 200. The antenna 220 is partially housed by the additional cavity in the carbon fiber plugging portion. Advantageously, the partial encapsulation of the antenna 220 can maximize the amount of carbon fiber plugging portion material available for the given area while ensuring that each component is fully constrained.

[0044] Figure 2B illustrates the carbon fiber plugging portion 210 according to one embodiment of this disclosure. The carbon fiber plugging portion 210 of Figure 2B can be used in the card body design of Figure 2A. According to the illustrated example, the carbon fiber plugging portion 210 can be approximately rectangular with rounded corners. The radius of the rounded edges can be approximately 2.750 mm. In one embodiment, the carbon fiber plugging portion 210 can be approximately 45.281 mm wide and approximately 47.831 mm high. Variations in the shape and geometry of the carbon fiber plugging portion 210 are compatible with this disclosure. According to one embodiment, the carbon fiber plugging part 210 may include an antenna cutout 215, also called an additional cavity, for antenna placement.The antenna can be partially housed by the additional cavity in the carbon fiber plug. In other words, the carbon fiber plug 210 of [Fig. 2A] and [Fig. 2B] can partially encapsulate the antenna. The antenna cutout 215 can be part of the antenna. For example, the antenna cutout 215 can be a rounded cutout designed to fit around a rounded part of the antenna, as shown in [Fig. 2B]. In one embodiment, the radius of the curve of the cutout 215 can be approximately 12.921 mm. The cutout 215 can be approximately symmetrical or asymmetrical. For example, one edge of the cutout 215 can extend beyond an opposite edge. In one embodiment, the geometry of the antenna cutout 215 can be designed to minimize manufacturing time.For example, the antenna cutout 215 can be shaped for easy placement of the antenna inside the cutout. The antenna cutout 215 can be centered along any dimension of the carbon fiber plugging portion 210 or can be positioned anywhere inside the portion of . Carbon fiber plug 210. The antenna cutout 215 can be cut through the carbon fiber plug 210 such that the antenna is exposed at the top and bottom surfaces of the carbon fiber plug when the antenna is placed in the antenna cutout 215. In one embodiment, the carbon fiber plug can be approximately 0.200 mm to 0.840 mm thick, for example, approximately 0.305 mm thick. In one embodiment, the card body can be approximately 0.200 mm to 0.840 mm thick, for example, 0.305 mm thick. Preferably, the thickness of the card body is equal to the thickness of the carbon fiber plug.

[0045] Fig. 2A is an illustration of what can also be defined as: - a card body 200, the card body defining a main cavity, the main cavity having a continuous surface defined by an interior surface of the card body, - a carbon fiber plugging part 210, the carbon fiber plugging part being housed inside the main cavity, - an antenna 220, the antenna being housed inside the main cavity, the carbon fiber plugging part defining an additional cavity in the carbon fiber plugging part and the antenna being partially housed by the additional cavity in the carbon fiber plugging part.

[0046] Figure 3A illustrates a carbon fiber plug 310 and an antenna 320 incorporated into a card body 300, according to an embodiment of this disclosure. The card body 300 can form the body of the smart card. The card body 300 can be approximately rectangular with rounded corners. Illustrative card and component dimensions are shown here as non-limiting, illustrative embodiments. In one embodiment, the card body 300 can be approximately 85.928 mm wide and 54.331 mm high.In one embodiment, the carbon fiber sealing portion 310 is composed of carbon fibers, and the card body 300 may be composed of a metal, for example, stainless steel or another machinable metal, or a polymer, for example, polyvinyl chloride (commonly referred to as PVC) or polycarbonates (commonly referred to as PC). In one embodiment, the antenna 320 may include any circuit elements used for smart card functionality, including, but not limited to, processing circuit elements and memory. A main cavity may be formed in the card body 300 to completely contain and encapsulate the carbon fiber sealing portion 310. Thus, the card body defines a main cavity having a... A continuous surface defined by an interior surface of the card body. In one embodiment, the main cavity can be completely contained within the card body 300 such that the continuous surface of the main cavity is discontinuous with the edges of the card body 300. The carbon fiber plugging portion 310 is not in contact with the edges of the card body 300 when placed in the main cavity, which is completely contained within the card body 300. Advantageously, the continuous surface of the main cavity and the edges of the card body are separated by a minimum of 0.5 mm. In another embodiment, the continuous surface of the main cavity can be continuous with respect to one or more edges of the card body 300 such that the carbon fiber plugging portion 310 is in contact with one or more edges of the card body 300 when placed in the main cavity.In this embodiment, the card body protects the sealing portion while limiting the exposure of the carbon fibers on at least one edge of the smart card. In some embodiments, the main cavity may include a space for the antenna 320. The carbon fiber sealing portion 310 may occupy any part of the card body area 300. In one embodiment, the main cavity may be made in a first external surface (for example, the top surface) of the card body such that the carbon fiber sealing portion 310 may be exposed at the top surface of the card body 300 when the carbon fiber sealing portion 310 is placed in the main cavity.In some embodiments, the main cavity may be a cutout through the first surface (e.g., the top surface) of the card body 300 and the opposite second outer surface (e.g., the bottom surface) of the card body 300 such that the carbon fiber plugging portion may be exposed at both the top and bottom surfaces of the card body 300 when the carbon fiber plugging portion is placed in the main cavity. In one embodiment, the antenna 320 may be placed in the card body 300 so that the antenna is exposed at both the top and bottom surfaces of the card body. Exposing the antenna 320 on both sides of the card body may provide improved reception for wireless data transmission.

[0047] In one embodiment, the carbon fiber plugging portion 310 may be separate from the antenna 320 in the card body 300, as shown in [Fig. 3A]. The card body 300 may include a first main cavity for the carbon fiber plugging portion 310 and a second main cavity for the antenna 320. The card body defines a first main cavity and a second main cavity, each main cavity of the first and second main cavities having a continuous surface defined by an inner surface of the card body. The first main cavity and the second main cavity are disjointed. The carbon fiber plugging part 310 and the antenna 320 can be positioned within the card body 300 such that the two components do not contact each other. The carbon fiber plugging part 310 and the antenna 320 can each be independently constrained by the card body 300. The size and geometry of the carbon fiber plugging part 310 can depend on the size and geometry of the antenna 320. In some implementations, the separation between the carbon fiber plugging part 310 and the antenna 320 can lead to the most efficient use of carbon fibers in the carbon fiber plugging part 310, since the carbon fiber plugging part 310 does not involve any material cutting.The more uniform shape of the 310 carbon fiber plugging portion in the design example in [Fig. 3A] can reduce manufacturing time and costs. Advantageously, the edges of the card body and the continuous surface of the first and second main cavities are spaced at least 0.5 mm apart. The distances between the continuous surface of the first main cavity and the edges of the card body are indicated by A, B, C, and D in [Fig. 3A]. The distances between the continuous surface of the second main cavity and the edges of the card body are indicated by E, F, G, and H in [Fig. 3A].

[0048] Figure 3B illustrates the carbon fiber 310 plugging portion according to one embodiment of this disclosure. The carbon fiber 310 plugging portion of Figure 3B can be used in the card body design of Figure 3A. As illustrated, the carbon fiber 310 plugging portion can be approximately rectangular with rounded corners. The radius of the rounded edges can be approximately 2.750 mm. In one embodiment, the carbon fiber 310 plugging portion can be approximately 34 mm wide and approximately 47.831 mm high. Variations in the shape and geometry of the carbon fiber 310 plugging portion are compatible with this disclosure.In one embodiment, the carbon fiber plugging portion 310 may not have an antenna cutout, since the carbon fiber plugging portion 310 can be positioned separately from the antenna. In other words, in this embodiment, the carbon fiber plugging portion 310 does not define any additional cavity. In another embodiment, the carbon fiber plugging portion may have a bend 315 to fit around the antenna. The radius of the bend 315 may be, for example, approximately 15.671 mm. The bend 315 may allow the carbon fiber plugging portion and the antenna to be positioned in close proximity without overlapping or contact between them. The carbon fiber plugging section and the antenna. In one embodiment, the carbon fiber plugging section can be approximately 0.200 mm to 0.840 mm thick, for example, approximately 0.305 mm thick. In one embodiment, the card body can be approximately 0.200 mm to 0.840 mm thick, for example, approximately 0.305 mm thick. Preferably, the thickness of the card body is equal to the thickness of the carbon fiber plugging section.

[0049] Fig. 3A is an illustration of what can also be defined as: - a card body 300, the card body defining at least one main cavity, each main cavity of the at least one main cavity having a continuous surface defined by an interior surface of the card body, - a carbon fiber plugging part 310, the carbon fiber plugging part being housed inside the at least one main cavity, - an antenna 320, the antenna being housed inside the at least one main cavity, the at least one main cavity being a first main cavity and a second main cavity, the first main cavity and the second main cavity part being disjoint, and the carbon fiber plugging part 320 being housed inside the first main cavity and the antenna 320 being housed inside the second main cavity.

[0050] According to one embodiment, the antenna may be a peripheral antenna located near one or more edges of the card body. For example, the antenna may be a length of circuit elements positioned along any length of the perimeter of the card body. In some embodiments, the peripheral antenna may be located near the edges of the card body but not directly at the edges of the card body. The card body (for example, a stainless steel card body) may still form the edges of the smart card to ensure the durability of the smart card. The peripheral antenna may allow for different configurations and proximities for reading a smart card. In one embodiment, the peripheral antenna may surround the carbon fiber plugging portion. For example, the carbon fiber plugging portion may be a rectangular plugging portion.The carbon fiber plugging portion can be placed in a main cavity in the card body, and the peripheral antenna can be positioned around the carbon fiber plugging portion. In one embodiment, the peripheral antenna can be in contact with the carbon fiber plugging portion and can form a border around the carbon fiber plugging portion. In one embodiment, there may be a separation between the carbon fiber plugging portion and the peripheral antenna. In one embodiment, the carbon fiber plugging portion may include an antenna cutout. for the placement of the peripheral antenna. For example, the carbon fiber plugging section may have an antenna cutout in the form of a rectangular outline. The peripheral antenna can be fully or partially housed within this antenna cutout, also called an additional cavity, in the carbon fiber plugging section. In other words, the peripheral antenna can be completely or partially encapsulated by the carbon fiber plugging section.

[0051] Advantageously, any of the boards described herein can be manufactured with a variety of antenna and chip designs and standards. The illustrative examples provided in this disclosure highlight a number of positions and relationships between the board body, the carbon fiber plugging portion, and the antenna. These positions can be implemented with a variety of board body shapes, carbon fiber plugging portion shapes, and antenna shapes and sizes. For example, a circular carbon fiber plugging portion can fully or partially encapsulate an antenna. According to one embodiment, any of the boards disclosed herein can be compatible with more than one antenna or circuit module. For example, a board body and / or a carbon fiber plugging portion can have more than one cutout for more than one antenna.In one embodiment, a card body may include more than one carbon fiber plugging portion. For example, an antenna may be positioned in the center of the card body. A first carbon fiber plugging portion may be positioned on one side of the antenna, and a second carbon fiber plugging portion may be positioned on a second side of the antenna.

[0052] Fig. 4 is an illustration of a 400 card body comprising a first A main cavity 410 for a carbon fiber plugging portion and a second main cavity 420 for an antenna, according to one embodiment of this disclosure. The first main cavity and the second main cavity are separate. In the illustration given by way of example, the carbon fiber plugging portion and the antenna can be positioned in the card body 400 with a separation between the two components, as in [Fig. 3A] and [Fig. 3B]. In some embodiments, the first main cavity 410 and the second main cavity 420 can be combined into a single main cavity in the card body, such as when the carbon fiber plugging portion completely or partially encapsulates the antenna.According to one embodiment, the card body 400 can be cut from a film or sheet, referred to as the body sheet in the remainder of the description, for example a metallic film such as stainless steel film, or a polymer film, such as PVC or PC film. For example, a . A number of card bodies can be cut from a film using laser cutting, chemical etching, punching, or computer numerical control (CNC) machining. The film can contain, for example, 48 card bodies and can be further processed as a single sheet before the individual card bodies are separated from the film. In one embodiment, at least one master cavity can be chemically etched into the card body. Chemical etching may involve the use of a photosensitive resin to transfer a pattern onto the card body. Chemical etching can be used to create precise cavities in a highly reproducible manner without placing the card body under mechanical stress. The depth of each master cavity can be modulated by the chemical etching process.In one embodiment, the thickness of the carbon fiber plugging portion can be approximately equal to the thickness of the card body. The carbon fiber plugging portion can be flush against the upper and lower surfaces of the card body when the carbon fiber plugging portion is placed in the first main cavity 410. In one embodiment, the thickness of the antenna can be approximately equal to the thickness of the card body.

[0053] Figure 5 illustrates a film or sheet containing multiple card bodies, according to one embodiment of this disclosure. In one embodiment, the 500 body sheet may be a metallic sheet such as stainless steel or a polymer sheet such as PVC or PC, as explained herein. The 500 body sheet may be cut and engraved to create multiple card bodies, for example, 30 card bodies as illustrated in Figure 5. As an illustrative embodiment, the 500 body sheet may be approximately 590.5 mm wide and 191.1 mm high. In one embodiment, each card body may be surrounded by a border. The border may serve as a separator between card bodies to facilitate assembly and may also form a boundary for individualizing or separating the card bodies from the sheet after assembly.In one embodiment, the 500 body sheet can be used to create more than one card body design. For example, the 500 body sheet can include 510 card bodies for a carbon fiber plug part that fully encapsulates an antenna, 520 card bodies for a carbon fiber plug part that partially encapsulates an antenna, and 530 card bodies for a carbon fiber plug part positioned separately from an antenna. The primary cavity or cavities for each of the card body designs can be chemically etched into each of the 510, 520, and 530 card bodies. For example, a single primary cavity 511 in the shape of a carbon fiber plug part can be chemically etched into each body. of card 510. The single main cavity 511 can contain a carbon fiber plug portion that completely encapsulates an antenna. In a given example design, a main cavity 521 can be chemically etched into each card body 520. The main cavity 521 can contain a carbon fiber plug portion and an antenna, the carbon fiber plug portion partially encapsulating an antenna. In a given example design, a first main cavity 531 and a second main cavity 532 can be chemically etched into each card body 530. The first main cavity 531 can contain a carbon fiber plug portion, and the second main cavity 532 can contain an antenna.The first main cavity 531 and the second main cavity 532 can be chemically etched with a separation between them, thus keeping them disjoint. This separation can be contrasted with the partial encapsulation design of the card body 520, in which the carbon fiber plug and the antenna can fit within a single main cavity 521. Illustrative dimensions of the body sheet 500 and each of the card bodies 510, 520, and 530 are shown in [Fig. 5]. Each of the card bodies 510, 520, and 530 can be rectangular with rounded edges. In one embodiment, the card bodies can be evenly spaced across the entire body sheet 500 with the same spacing between each card body.Each card body can have the same dimensions or at least one dimension (e.g., height, width) in common. A 500-sheet card body can be used for a single card body design or for more than one card body design.

[0054] Figure 6A is a side exploded view of a fully assembled smart card 600, according to an embodiment illustrative of this disclosure. The smart card 600 may include the card body 610. The card body 610 may be a metallic body such as a stainless steel body or a polymer body such as a PVC or PC body. The card body 610 may form the central portion of the smart card 600. In one embodiment, the smart card 600 may include at least one binder layer 601 and at least one polymer layer 602 above the card body 610. In another embodiment, the smart card 600 may include at least one binder layer 611 and at least one polymer layer 612 on the lower portion of the smart card. In one embodiment, the binder layers 601, 611 can be resin layers. The resin can be monomer or polymer.The resin may be a curable resin, including, but not limited to, ester group resins, acetal resins, resins of . Casting, impregnation resins, unsaturated resins, saturated resins, urethane acrylate, silicone acrylate, epoxy acrylate, methacrylate, acrylate, or urethane. In one embodiment, the binder layer may be an adhesive layer. In one embodiment, the polymer layers 602, 612 may be polyvinyl chloride (PVC) or an epoxy-based compound. In one embodiment, the binder and polymer layers may be completely or partially transparent. According to one embodiment, the smart card 600 may further comprise a top decorative layer 603 and a top cover layer 604 above the polymer layer 602. The top decorative layer 603 and / or the top cover layer 604 may be completely or partially transparent to reveal the internal carbon fiber components.The top decorative layer 603 may, in some examples, include designs such as a logo or identifying information relating to the issuer or cardholder. In one embodiment, the smart card 600 may have a bottom decorative layer 613 and a bottom overlay layer 614 above the polymer layer 612 on the underside of the smart card. Each layer may be a rectangular layer with rounded edges having approximately the same dimensions as the card body 610. In one embodiment, the layers of the smart card 600 may be arranged so that the sides of the card body 610 remain exposed. For example, the layers may not wrap around the sides of the card body 610.The exposed edges of the 610 card body maintain the smart card's durability and prevent smart card users from coming into contact with carbon fiber particles. The exposed edges of the 610 card body can be colored when the card body is made of PVC. The exposed edges of the 610 card body are stiffer, more robust, and give the user a metallic feel when the card body is made of metal.

[0055] According to an illustrative embodiment, the top cover layer 604 and the top decorative layer 603 may be plastic layers, including, but not limited to, polyvinyl chloride (PVC) or polyvinyl chloroacetate (PVCA). The top cover layer 604 may be approximately 45 µm to approximately 60 µm thick. The top decorative layer 603 may be approximately 127 µm thick. In one embodiment, the top cover layer 604 and the top decorative layer 603 may be grouped together before being laid on the card. Similarly, the bottom cover layer 614 and the bottom decorative layer 613 may be grouped together before being laid. In one embodiment, the top polymer layer 602 and the top binder layer 601 may be The card body 610 may be approximately 50 µm thick in combination. In one embodiment, the card body 610 may be approximately 330 µm thick. The card body 610 may include the carbon fiber sealing portion and the antenna as described herein. The bottom binder layer 611 and the bottom polymer layer 612 may be approximately 50 µm to approximately 75 µm thick in combination. The bottom decorative layer 613 may be a PVC layer and may be approximately 127 µm thick. The bottom cover layer 614 may be a PVC layer and may be approximately 45 µm to 60 µm thick. In one embodiment, the bottom cover layer 614 may include a magnetic stripe for swiping the smart card through a reader device such as a payment terminal.It will be understood that the dimensions listed here are presented as illustrative embodiments, and that variations in geometries and layer thicknesses are compatible with this disclosure. A top cover layer 604 and a bottom cover layer 614 made of PVC are advantageous for protecting the top decorative layer 603 and the bottom decorative layer 613 while facilitating hot stamping of any hologram and signature panel, and simplifying card personalization using existing equipment, for example, laser and thermal transfer machines.

[0056] Fig. 6B is an isometric exploded view of a fully assembled 600 smart card, according to an embodiment illustrative of the present disclosure. The smart card 600 may include the upper cover layer 604, the upper decorative layer 603, the upper polymer layer 602, and the upper binder layer 601 as a series of layers stacked on the upper surface of the card body 610. The smart card 600 may further include the lower binder layer 611, the lower polymer layer 612, the lower decorative layer 613, and the lower cover layer 614 as a series of layers stacked below the lower surface of the card body 610. In one embodiment, the card body 610 may be the thickest layer of the smart card 600. In one embodiment, the decorative and cover layers may differ for visual or aesthetic purposes.In one embodiment, the decorative and / or cover layers may have engraved or embossed parts. In one embodiment, at least one of the decorative layers may have a window, the card body being visible through the window in the decorative layer. The window may be, for example, a cutout in the decorative and / or cover layers. The cutout may be covered with a transparent material such as a clear plastic or resin. In one embodiment, the window may allow the card body and / or part of it to be seen. Carbon fiber plugs. Visibility of the card body and / or carbon fibers can provide aesthetic appeal. Visibility of the card body and / or carbon fibers can also allow a person handling the card to see if there is any breakage or other change to the internal components.

[0057] In one embodiment, the lower polymer layer, the lower binder layer, the card body, the upper binder layer, and the upper polymer layer can be formed as an inset within the smart card. The inset can be assembled and placed as a single insert. Figure 7 is an exploded view of an inset 700 for a single smart card according to an embodiment illustrative of this disclosure. The inset 700 can comprise the lower polymer layer 712, the lower binder layer 711, the card body 710 including the carbon fiber sealing portion and the antenna, the upper binder layer 701, and the upper polymer layer 702. According to one embodiment, each of the monomer or polymer layers can be approximately 25 µm thick. In one embodiment, the monomer or polymer layers can be of different thicknesses.In one embodiment, each of the binder layers can be approximately 25 µm thick. In another embodiment, the binder layers can be of different thicknesses.

[0058] Figure 8 is a method 800 for assembling an inlay, according to an embodiment illustrative of this disclosure. The lower polymer can be supplied in step 810. The lower binder layer can be dispensed over the lower polymer layer in step 820. The card body can then be placed over the lower binder layer in step 830. The card body can have at least one main cavity. In one embodiment, at least one main cavity can be chemically etched into the card body. The carbon fiber plugging portion can be placed in at least one main cavity in the card body in step 840. The carbon fiber plugging portion can be cut from a sheet or film of carbon fiber using a laser, water jet, or computer numerical control (CNC) machining.For example, a carbon fiber plugging portion can be cut from a sheet of carbon fiber film using lasers or mechanical cutting tools. The antenna can be placed in at least one main cavity in the board body in step 850. In one embodiment, the carbon fiber plugging portion and the antenna can be placed in the same main cavity. The carbon fiber plugging portion can completely or partially encapsulate the antenna, as described here. In one embodiment, the carbon fiber plugging portion can be placed in a first main cavity in the board body. The antenna can be placed in a second main cavity in the card body. In one embodiment, the carbon fiber plug and the antenna can be manually placed in at least one main cavity. In another embodiment, the carbon fiber plug and the antenna can be placed in at least one main cavity by a pick-and-place machine. According to one embodiment, the placement of the carbon fiber plug and the antenna can be inspected and adjusted before additional layers are dispensed over the card body. The top binder layer can be dispensed over the card body in step 860 after the carbon fiber plug and the antenna have been placed in the card body. The top polymer layer can be dispensed over the top binder layer in step 870.

[0059] In one embodiment, the inlay can be finalized by placing the assembled inlay layers in a vacuum chamber and applying a vacuum in step 880. In the vacuum chamber, a plate (for example, an acrylic or stainless steel plate) can be placed over the layers to apply weight and hold the layers in place while the vacuum is applied to the chamber. As an illustrative method, the plate can be approximately 400 mm by 600 mm and can have 9 to 30 embedded N45 magnets, 25 mm in diameter and 3 mm thick, to hold the card body in place when the card body is made of metal. As another illustrative method, when the card body is made of polymer, the plate is held down with a flat plastic piece to hold the card body in place during the vacuum.The vacuum can incorporate all the materials between the top and bottom polymer layers to reduce errors. In one embodiment, the vacuum can be applied for approximately 60 to 90 seconds. After the vacuum has incorporated all the materials and layers, the inlay can be easily handled without the individual layers or components shifting. It will be understood that the inlays can be assembled as an inlay sheet, with the inlay sheet potentially containing more than one inlay (for example, 30 inlays). Each layer in the inlay can be deposited as a sheet. The inlay sheet can be incorporated into the vacuum chamber. In one embodiment, each inlay can be cut from the sheet using a laser cutting process or similar method.In one embodiment, the layers of the inlay can be individually cut, for example by laser cutting, before or during assembly. The inlays or cards can be separated from the sheet in an individualization process after the inlay or the entire card has been assembled. Some card embodiments described here may offer [advantages / features]. Advantages for assembly. For example, placing the carbon fiber plugging part and the antenna in a single main cavity can reduce placement time for the operator compared to placing components in separate main cavities.

[0060] Figure 9 is an exploded view of a smart card sheet 900 according to an embodiment illustrative of this disclosure. The smart cards can be assembled into layered sheets. In one example, a sheet may contain 30 smart cards. In one embodiment, the polymer layers, binder layers, and card bodies can be assembled as an inlay sheet 910, as described herein with reference to Figure 7 and Figure 8. The remaining layers, including the cover and decorative layers, can be arranged in sheets surrounding the inlay sheet. According to one embodiment, the bottom cover sheet 914 may be approximately 45 µm thick. The bottom decorative sheet 913 may be a printed center sheet and may be approximately 127 µm thick. As an example, the decorative sheet may be screen-printed or printed by a similar process.In one embodiment, magnetic strips can be printed onto the lower decorative sheet 913 using magnetic inks. The inlay sheet 910 can be positioned above the lower decorative sheet 913. The inlay sheet 910 can comprise a body sheet surrounded by an upper polymer sheet and an upper binder sheet, and a lower binder sheet and a lower polymer sheet. Each body of the sheet includes a carbon fiber plugging portion and an antenna. The inlay sheet 910 can be approximately 450 µm thick. The upper decorative layer 903 can be a printed central portion positioned above the inlay sheet 910 and can be approximately 127 µm thick. The upper decorative sheet 903 can be printed with the same design as the lower decorative sheet 913 or with a different design.The top cover sheet 904 can then be placed over the top decorative sheet 903 and can be approximately 45 µm thick. In one embodiment, the cover sheets can be transparent. A top cover sheet 904 and a bottom cover sheet 914 made of PVC are advantageous for protecting the top decorative sheet 903 and the bottom decorative sheet 913 while facilitating hot stamping of any hologram and signature panel, and simplifying card personalization using existing equipment, for example, laser and thermal transfer machines.

[0061] Figure 10 is a method for assembling a smart card sheet comprising carbon fiber sealing parts, according to an embodiment illustrative of this disclosure. An inlay sheet, for example, an inlay sheet 910 shown in [Fig. 9], can first be assembled in step 1010. The inlay sheet can be assembled according to the methods described herein with reference to [Fig. 8]. The bottom cover sheet can be positioned in step 1020. The bottom decorative sheet can be printed and positioned over the bottom cover sheet in step 1030. The inlay sheet can be positioned over the bottom decorative sheet in step 1040. The top decorative sheet can be printed and positioned over the inlay sheet in step 1050. The top cover sheet can be positioned over the top decorative sheet in step 1060.In one embodiment, plastic welding can secure the layers in place while the card sheet is being assembled. Plastic sheets can temporarily hold the layers together while the sheets are being layered. In another embodiment, heat sealing can secure the layers in place during assembly. Heat sealing can reduce the risk of binder layer contamination.

[0062] According to some embodiments, the smart card sheet can be laminated in step 1070 after the sheets have been bundled. Lamination can hold the layers together and protect the card finish and increase the card's strength. Advantageously, the bundled overlay, decorative, and inlay layers and the lamination of the card sheet are not affected by the placement of the carbon fiber filler parts in the card bodies. In one embodiment, the plastic from the plastic welding can be removed after lamination.

[0063] In one embodiment, the smart cards can be ribbed after lamination. In some embodiments, a varnish can be added to both surfaces of the smart card after assembly. The varnish can prevent scratching. In one embodiment, the varnish can replace one or more layers of the smart card to make it thinner. According to some embodiments, the varnish can mask components or any edges or contours in the smart card. For example, the varnish can completely or partially mask the main cavity in the card body where the carbon fiber plugging portion is located. After the smart card sheet has been assembled and laminated, the individual assembled smart cards can be separated from the sheet in the individualization process.Each smart card can comprise a card body, the card body including the carbon fiber sealing portion and an antenna. The arrangement of the carbon fiber sealing portion and the antenna can be determined according to any of the embodiments described herein in order to adjust the... weight, mechanical characteristics and robustness of the smart card, while limiting contact between smart card users and carbon fiber particles, and maintaining a smart card that is configured for contactless card reading (and possibly contact card reading).

[0064] Although this specification contains many specific implementation details, these should not be regarded as limitations of the scope which may be claimed, but rather as descriptions of features which may be specific to particular embodiments.

[0065] Certain features described in this specification in the context of separate embodiments may also be implemented in combination within a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features of a claimed combination may in some cases be removed from the combination, and the claimed combination may relate to a subcombination or a variation of a subcombination.

[0066] Similarly, although operations are described in the drawings in a particular order, this should not be understood as requiring that such operations be carried out in the particular order shown or in a sequential order, or that all the illustrated operations be carried out, to obtain desirable results. Furthermore, the separation of the various system modules and components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the program components and systems described can generally be integrated together into a single component or grouped into multiple components.

[0067] Specific embodiments of the object of the invention have been described. Other embodiments are included within the scope of the following claims. For example, the actions listed in the claims can be performed in a different order and still achieve desirable results. As another example, the processes described in the accompanying figures do not necessarily require the specific order shown to achieve desirable results. In some cases, multitasking and parallel processing may be advantageous.

[0068] Obviously, many modifications and variations are possible in light of the teachings above. It is therefore important to understand that, within the scope of the In addition to the attached claims, embodiments of this disclosure may be implemented in a manner different from that specifically described herein.

[0069] Embodiments of this disclosure may also be as described below.

[0070] Embedding 1 is an inlay layer of a smart card, comprising a card body, the card body defining at least one main cavity, each main cavity of the at least one main cavity having a continuous surface defined by an interior surface of the card body; a carbon fiber plugging portion, the carbon fiber plugging portion being housed inside the at least one main cavity; and an antenna, the antenna being housed inside the at least one main cavity.

[0071] Embodiment 2 is the inlay layer of embodiment 1, the card body being composed of a metal or a polymer.

[0072] Embodiment 3 is the inlay layer of any of embodiments 1 and 2, the continuous surface of at least one main cavity being discontinuous with an edge of the card body.

[0073] Embodiment 4 is the inlay layer of embodiment 3, the continuous surface of at least one main cavity and the edges of the card body being spaced at least 0.5 mm apart.

[0074] Embodiment 5 is the inlay layer of any of the embodiments 1 to 4, the carbon fiber plugging portion defining an additional cavity in the carbon fiber plugging portion.

[0075] Embodiment 6 is the inlay layer of embodiment 5, the antenna being housed completely or partially by the additional cavity in the carbon fiber plugging part.

[0076] The embodiment 7 is the inlay layer of any of the embodiments 5 and 6, the additional cavity in the carbon fiber plugging portion extending through the upper and lower outer surfaces of the carbon fiber plugging portion.

[0077] Embodiment 8 is the inlay layer of any of embodiments 1 to 7, the at least one main cavity being a first main cavity and a second main cavity, and the first main cavity and the second main cavity being disjoint.

[0078] The embodiment 9 is the inlay layer of the embodiment 8, the carbon fiber plugging part being disposed, housed, inside the first main cavity and the antenna being disposed, housed, inside the second main cavity.

[0079] The embodiment 10 is a smart card, comprising an inlay layer of any of the embodiments 1 to 9, and a monomer or polymer layer disposed on an outer surface of the inlay layer, the monomer or polymer layer being in contact with an outer surface of the carbon fiber sealing portion.

[0080] The embodiment 11 is a method for manufacturing a smart card inlay, the method comprising forming a card body from a metal or polymer; forming at least one main cavity in the card body, each main cavity of the at least one main cavity having a continuous surface defined by an inner surface of the card body; forming a carbon fiber plugging portion from carbon fibers; deposition of the carbon fiber plugging portion in the at least one main cavity in the card body; and deposition of an antenna in the at least one main cavity in the card body.

[0081] Embodiment 12 is the method of embodiment 11, further comprising the formation of an additional cavity in the carbon fibre plugging portion.

[0082] Embodiment 13 is the method of embodiment 12, the antenna being deposited partially or completely in the additional cavity in the carbon fiber plugging part.

[0083] The embodiment 14 is the method of any embodiment 11 to 13, the at least one main cavity being a first main cavity and a second main cavity, the first main cavity and the second main cavity being disjoint, and the carbon fiber plugging portion being deposited in the first main cavity and the antenna being deposited in the second main cavity.

[0084] Embodiment 15 is the method of any of embodiments 11 to 14, the continuous surface of at least one main cavity being discontinuous with an edge of the card body.

[0085] Thus, the above discussion discloses and describes only illustrative embodiments of this disclosure. As those skilled in the art will understand, this disclosure can be made in other specific forms without departing from its spirit. Accordingly, the disclosure of this disclosure is intended to illustrate, in a non-limiting manner, the scope of the disclosure, as well as other claims. The disclosure, including any readily recognizable variations of the teachings presented herein, defines, in part, the scope of the above claim terminology so that no inventive object is dedicated to the public.

Claims

Demands

1. Inlay layer of a smart card, comprising: - a card body (100, 200, 300, 610, 710), the card body defining at least one main cavity, each main cavity (511, 521, 531, 532) of the at least one main cavity having a continuous surface defined by an interior surface of the card body; - a carbon fiber plugging portion (110, 210, 310), the carbon fiber plugging portion being housed inside the at least one main cavity; and - an antenna (120, 220, 320), the antenna being housed inside the at least one main cavity.

2. Inlay layer according to claim 1, the card body being composed of a metal or a polymer.

3. Inlay layer according to any one of claims 1 to 2, the continuous surface of at least one main cavity being discontinuous with an edge of the card body.

4. Inlay layer according to claim 3, the continuous surface of at least one main cavity and the edges of the card body being spaced at least 0.5 mm apart.

5. Inlay layer according to any one of claims 1 to 4, the carbon fibre plugging portion defining an additional cavity in the carbon fibre plugging portion.

6. Inlay layer according to claim 5, the antenna being housed completely or partially by the additional cavity in the carbon fibre plugging part.

7. Inlay layer according to any one of claims 5 to 6, the additional cavity in the carbon fibre plugging portion extending through the upper and lower outer surfaces of the carbon fibre plugging portion.

8. Inlay layer according to any one of claims 1 to 7, the at least one main cavity being a first main cavity and a second main cavity, the first main cavity and the second main cavity being disjoint, and the carbon fibre plugging portion (320) being housed inside the first main cavity and the antenna (320) being housed inside the second main cavity.

9. Smart card, including: - an inlay layer according to any one of claims 1 to 8; and - a layer of monomer or polymer disposed on an outer surface of the inlay layer, the layer of monomer or polymer being in contact with an outer surface of the carbon fiber sealing part.

10. A method for manufacturing a smart card inlay, the method comprising: - forming a card body from a metal or polymer; - forming at least one main cavity in the card body, each main cavity of the at least one main cavity having a continuous surface defined by an interior surface of the card body; - forming a carbon fiber plugging portion from carbon fibers; - deposition of the carbon fiber plugging portion in the at least one main cavity in the card body; and - deposition of an antenna in the at least one main cavity in the card body.

11. A method according to claim 10, further comprising the formation of an additional cavity in the carbon fiber plugging portion, the antenna being housed partially or completely in the additional cavity in the carbon fiber plugging portion.

12. A method according to any one of claims 10 to 11, wherein at least one main cavity is a first main cavity and a second main cavity, the first main cavity and the second main cavity being disjoint, and the carbon fibre plugging portion being deposited in the first main cavity and the antenna being deposited in the second main cavity.

Images