Highly flexible foil composite material and its use in card bodies

A method for manufacturing a card body configured as a portable data carrier, the method comprising:

• forming a plurality of plastic layers to include a card core and at least two cover layers, the card core being made of at least one inner core layer, the card core being formed between the at least two cover layers, a first cover layer being in direct contact with a first surface of the card core and a second cover layer being in direct contact with a second surface of the card core,
• wherein, in the step of forming the plurality of plastic layers,
• the plastic layers are laminated to each other in one work operation or in several work operations, and
• the card core, the first cover layer, or the second cover layer includes a foil composite material that comprises a coextrusion of at least one first outer layer plastic material, at least one second outer layer plastic material, and at least one inner layer plastic material,
• the foil composite material being formed by
• coextruding and merging the at least one first outer layer plastic material, the at least one second outer layer plastic material, and the at least one inner layer plastic material such that the foil composite material includes
• an inner plastic layer formed between a first outer plastic layer and a second outer plastic layer,
• the first outer plastic layer being in direct contact with a first surface of the inner plastic layer, and
• the second outer plastic layer being in direct contact with a second surface of the inner plastic layer, the first surface of the inner plastic layer being opposite from the second surface of the inner plastic layer,
• wherein the at least one first outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers,
• the at least one second outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers, and
• the at least one inner layer plastic material comprises a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer,
• wherein the foil composite material is opaque, and
• wherein
• each of the first outer plastic layer and the second outer plastic layer are 0% thermoplastic elastomer, 85% to 95% thermoplastic polymer, and 15% to 5% filler,
• each of the first exterior plastic layer and the second exterior plastic layer are 20% to 50% thermoplastic elastomer, 75% to 35% thermoplastic polymer, and 5% to 15% filler, and
• the interior plastic layer is 50% to 70% thermoplastic elastomer, 45% to 15% thermoplastic polymer, and 5% to 15% filler.