Radio frequency identification card and hot lamination process for the manufacture of radio frequency identification cards

A hot lamination process for the manufacture of plastic cards, said process comprising the steps of:

• (a) providing first and second plastic core sheets;
• (b) positioning at least one electronic element in the absence of a non-electronic carrier directly between said first and second plastic core sheets to form a layered core;
• (c) positioning said core in a laminator apparatus, and subjecting said core to a heat and pressure cycle, said heat and pressure cycle comprising the steps of:
• (i) heating said core in said laminator, in the presence of a minimal first ram pressure, to a temperature which causes controlled flow of said plastic which makes up said first and second plastic core sheets;
• (ii) applying a second pressure uniformly across said core for encapsulating said at least one electronic element within said controlled flow plastic;
• (iii) subsequently cooling said core in conjunction with the concurrent application of a third pressure uniformly across said core, said core including and upper and lower surfaces;
• (d) printing on at least one of said upper and lower surfaces of said core such that a layer of ink is applied to at least a portion of said at least one upper and lower surface of said core.