Method of interlaying a metal core for a dual-layer electronic metal card

Abstract

A method of interlaying a metal core for a dual-layer electronic metal payment card. The metal core includes a metal layer having one or more openings formed therein (such as to receive a payment module or another electronic component or aesthetic feature). To interlay the metal core, the metal layer is laminated with a heat activated film layer and a release liner, and the laminated structure is subsequently placed on a heating plate. A polymer is applied only to the one or more openings. Using a containment structure placed over the metal core layer and a combination of heat, vacuum pressure, and pressurized inert gas, the method includes adhering and curing the polymer to the heat activated film to complete the lamination process. After curing, excess polymer is removed via a finishing edge (such as a grinder, a sander, a milling machine, or as similar edge).

Dependencies are inferred from the claim text.