Pre-lamination Core for Electronic Cards

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Solution Overview

Problem

Existing methods for manufacturing cards, such as smart cards and credit cards, require specialized equipment for assembling printed overlays and laminates, limiting the ability to create self-contained pre-lamination cores that can be shipped and incorporated into various electronic cards using conventional card-making equipment.

Innovation Solution

A pre-lamination core comprising a circuit or non-electronic component, a bottom cover sheet with heat seal material attached to a carrier sheet, a top cover sheet with heat seal material attached to another carrier sheet, and a layer of thermosetting material between them, allowing for injection molding and subsequent lamination with conventional equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If specialized equipment is used for assembling printed overlays and laminates, then manufacturing precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improveassembly precisionVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The card manufacturing process is divided into separate stages: pre-lamination core fabrication using injection molding, and final card assembly using conventional lamination equipment. This segmentation allows each stage to use appropriately matched equipment, eliminating the need for specialized assembly equipment while maintaining precision through the modular design of the pre-lamination core.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pre-lamination core is fabricated in advance using injection molding to precisely position electronic components and circuit boards within a rigid structure. This preliminary action establishes precise component placement before the final lamination step, eliminating the need for specialized equipment during the assembly stage while maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If conventional card-making equipment is used, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improveequipment simplicityVSAvoidassembly precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The manufacturing process is segmented into pre-lamination core fabrication (requiring high precision injection molding) and final card lamination (using conventional equipment). The pre-lamination core serves as a pre-assembled unit with precisely positioned components, allowing conventional lamination equipment to achieve the required final assembly precision without needing specialized capabilities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pre-lamination core is designed to be self-contained with all electronic components, circuit boards, and structural elements already precisely positioned within the rigid housing. This self-service design allows the core to be directly integrated into final cards using conventional equipment, as the precision requirements have already been satisfied during core fabrication.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If multi-layer sandwich structure is used, then card functionality is improved, but card thickness increases

Engineering Contradiction:

Improvecard functionalityVSAvoidcard thickness

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

Multiple functional layers (rigid housing, electronic components, circuit board, adhesive layers) are merged into a single integrated pre-lamination core through injection molding. This consolidation achieves the functionality of a multi-layer sandwich structure while minimizing thickness by eliminating the need for separate adhesive layers and mechanical fasteners between components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pre-lamination core utilizes composite construction combining rigid thermosetting plastic housing with flexible thermoplastic adhesive layers in a single molded structure. This composite approach provides both structural integrity and bonding capability within a minimized thickness profile, avoiding the need for separate structural and adhesive layers.

Inventive Principle:

Principle #40Composite materials

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

Enables the production of cards with reduced thickness and cost-effective manufacturing by allowing pre-lamination cores to be shipped and integrated into various cards using standard card-making processes, reducing equipment costs and enhancing compatibility with conventional card manufacturing systems.

Implementation Method 1

injecting a thermosetting polymeric material between the top and bottom cover sheets

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

heat seal material attached to a carrier sheet

Methodology Applied

Scientific EffectHeat sealing:

Implementation Method 3

performing a hot lamination process on the assembly

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentUS8657983B2Pre-lamination core and method for making a pre-lamination core for electronic cards and tags

Publication Date: 2014.02.25 INNOVATIER INC

AI summary

The disclosed pre-lamination core and the method of making such a pre-lamination core includes an electronic component or a non-electronic component, a bottom cover sheet, a top cover sheet, and a layer of thermosetting material between the bottom and top cover sheets. The pre-lamination core can be used in the manufacture of cards while using conventional equipment to apply top and bottom overlays to the pre-lamination core.