Hot lamination process for the manufacture of a combination contact/contactless smart card and product resulting therefrom

A process for incorporating at least one electronic element having at least one electronic subcomponent in the manufacture of a plastic card, comprising the steps of:

• (a) providing first and second plastic core sheets, at least one core sheet having a cavity formed therein;
• (b) positioning said at least one electronic element in the absence of a non-electronic carrier between said first and second plastic core sheets to form a layered core, said plastic core sheets defining a pair of inner and outer surface of said core, and said cavity positioned so as to expose said at least one electronic subcomponent therein;
• (c) inserting a spacer into said cavity, said spacer substantially filling said cavity and covering said at least one electronic subcomponent;
• (d) 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 for a first period of time;
• (ii) applying a first pressure to said core for a second period of time such that said at least one electronic element is encapsulated by said core;
• (iii) cooling said core while applying a second pressure to said core;
• (e) coating at least one of said outer surfaces of said core with a layer of ink;
• (f) removing said spacer from the cavity of said core.