Crosslinked Polymer Core Layer for Secure Information Cards

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Solution Overview

Problem

Information carrying cards, such as smart cards, face challenges in enhancing security and durability due to counterfeiting and information fraud, and need to accommodate increasing data storage and complex electronic components while withstanding flexing and maintaining productivity at a low cost.

Innovation Solution

A core layer for information carrying cards is developed using a cross-linked polymer composition over a thermoplastic layer with an inlay layer, which includes active or passive electronic components, and a method for forming this structure by dispensing a cross-linkable polymer composition over the inlay layer and curing it, optionally with UV light, to create a flexible and durable card.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional thermoplastic materials are used for information carrying cards, then manufacturing is simple and cost-effective, but security and durability are insufficient against counterfeiting and fraud

Engineering Contradiction:

Improvesecurity and durabilityVSAvoidmaterial structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses a composite material structure consisting of a thermoplastic layer combined with a crosslinked polymer composition. The thermoplastic layer provides ease of manufacture and flexibility, while the crosslinked polymer layer provides enhanced security, durability, and resistance to counterfeiting. This composite structure resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the card stores more information and has more complex IC components, then functionality and security are enhanced, but the card becomes more vulnerable to damage from flexing and has reduced durability

Engineering Contradiction:

Improveprotection of electronic componentsVSAvoiddurability during use

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The crosslinked polymer composition acts as a protective cushioning layer that is applied beforehand to protect the embedded IC components from mechanical damage during flexing. This layer provides a protective barrier that absorbs and distributes mechanical stresses, preventing damage to the sensitive electronic components while maintaining card flexibility.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a protective layer is added to protect electronic components, then security and component protection are improved, but manufacturing complexity and production cost increase

Engineering Contradiction:

Improvecomponent protectionVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the protective function with the existing card structure by integrating the crosslinked polymer composition as part of the card's core layer. This layer is applied and cured in a manner that combines it with the thermoplastic layer and embedded components in a single integrated structure, streamlining the manufacturing process while providing comprehensive protection.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If a crosslinked polymer composition is used to enhance security and protect components, then durability and fraud prevention are improved, but the curing process requires additional steps and energy input

Engineering Contradiction:

Improvefraud prevention and durabilityVSAvoidcuring energy input

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces traditional thermal curing processes with UV light curing for the crosslinked polymer composition. This substitution allows the polymer to cure rapidly at room temperature through photopolymerization, significantly reducing the energy input required compared to high-temperature thermal curing processes while achieving the same protective and security-enhancing effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances the security and durability of information carrying cards by providing a flexible and durable core layer that protects sensitive electronic components, reducing the risk of counterfeiting and information fraud, while maintaining low production costs and improved productivity.

Implementation Method 1

dispensing a cross-linkable polymer composition over the inlay layer and curing it, optionally with UV light

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS11170281B2Information carrying card comprising crosslinked polymer composition, and method of making the same

Publication Date: 2021.11.09 IDEMIA FRANCE SAS

AI summary

The disclosure provides a core layer for an information carrying card, resulting information carrying card, and methods of making the same. A core layer for an information carrying card comprises at least one thermoplastic layer having at least one cavity, an inlay layer, and, and a crosslinked polymer composition. At least one portion of the inlay layer is disposed inside the at least one cavity of the at least one thermoplastic layer. The crosslinked polymer composition is disposed over the at least one thermoplastic layer and contacting the inlay layer.