Transaction card with embedded electronic components and process for manufacture

1. A process for making a transaction card defined by a plurality of layers, the process comprising the steps of:

providing a first portion of the card, the first portion comprising a non-plastic layer having first and second faces and a thickness therebetween;

forming an opening in the non-plastic layer, the opening defined through the first face;

disposing embedded electronics in the opening;

providing a second portion of the card;

providing a fill disposed in portions of the opening not occupied by the embedded electronics and attaching the first portion of the card to the second portion of the card; and

wherein the step of providing the fill and attaching the first portion to the second portion of the card comprises the substeps of:

providing a transfer tape comprising unsupported adhesive disposed between a first release layer and a second release layer;

removing the first release layer and attaching the adhesive to one of (i) the second portion of the card, and (ii) the first face and the embedded electronics; and

removing the second release layer and attaching the adhesive to the other of (i) the second portion of the card, and (ii) the first face and the embedded electronics.

2. The process of claim 1 , further comprising tacking the electronics in the opening before disposing the fill in the opening.

3. The process of claim 1 , wherein the non-plastic layer comprises a coating on the second face, further comprising applying printed indicia to the coating.

4. The process of claim 1 , wherein the second portion comprises a plurality of layers.

5. The process of claim 4 , wherein the plurality of layers comprises a polymer layer, a magnetic stripe and a laser reactive layer.

6. The process of claim 1 , further comprising forming indicia on the second portion.

7. The process of claim 6 , wherein the step of forming the indicia comprises printing the indicia.

8. The process of claim 7 , wherein the second portion comprises a clear polymer layer, comprising printing the indicia on the clear polymer layer.

9. The process of claim 6 , wherein the second portion comprises a laser reactive layer and the step of forming the indicia comprises exposing the laser reactive layer to a laser.

10. The process of claim 1 , wherein the non-plastic layer comprises metal, and the process further comprises disposing a coating over a surface of the metal that enables printing on the coated metal surface.

11. The process of claim 1 , wherein the non-plastic layer comprises ceramic.

12. The process of claim 1 , wherein the transaction card has a first area defined by a first length and a first width, and the process comprises assembling the plurality of layers that define the card as a composite comprising a plurality of sheets, each sheet defining one of the plurality of layers and having a second area larger than the first area by a factor greater than two, wherein the process further comprises cutting the transaction card and one or more other transaction cards from the composite.

13. The process of claim 12 , further comprising personalizing each card after cutting the card from the composite.

14. The process of claim 1 , further comprising forming a pocket extending from the opening and having a pocket bottom with a depth less than the thickness.

15. The process of claim 1 , wherein the embedded electronics comprises at least a printed circuit board and a battery.

16. A process for making a transaction card defined by a plurality of layers, the process comprising the steps of:

providing a first portion of the card, the first portion comprising a non-plastic layer having first and second faces and a thickness therebetween;

forming an opening in the non-plastic layer, the opening defined through the first face;

disposing embedded electronics in the opening;

providing a second portion of the card;

providing a fill disposed in portions of the opening not occupied by the embedded electronics and attaching the first portion of the card to the second portion of the card; and

wherein the step of providing the fill and attaching the first portion to the second portion of the card comprises the substeps of:

laminating the first portion to the second portion in a lamination process at a temperature above room temperature, wherein the fill comprises a portion of a flowable polymer layer disposed in the second portion, wherein the flowable polymer layer is flowable at the lamination temperature.

17. The process of claim 16 , further comprising tacking the electronics in the opening before disposing the fill in the opening.

18. The process of claim 16 , wherein the non-plastic layer comprises a coating on the second face, further comprising applying printed indicia to the coating.

19. The process of claim 16 , wherein the second portion comprises a plurality of layers.

20. The process of claim 19 , wherein the plurality of layers comprises a polymer layer, a magnetic stripe and a laser reactive layer.

21. The process of claim 16 , further comprising forming indicia on the second portion.

22. The process of claim 21 , wherein the step of forming the indicia comprises printing the indicia.

23. The process of claim 22 , wherein a plurality of layers of the second portion comprises a clear polymer layer, comprising printing the indicia on the clear polymer layer.

24. The process of claim 21 , wherein the second portion comprises a laser reactive layer and the step of forming the indicia comprises exposing the laser reactive layer to a laser.

25. The process of claim 16 , wherein the non-plastic layer comprises metal, and the process further comprises disposing a coating over a surface of the metal that enables printing on the coated metal surface.

26. The process of claim 16 , wherein the non-plastic layer comprises ceramic.

27. The process of claim 16 , wherein the transaction card has a first area defined by a first length and a first width, and the process comprises assembling the plurality of layers that define the card as a composite comprising a plurality of sheets, each sheet defining one of the plurality of layers and having a second area larger than the first area by a factor greater than two, wherein the process further comprises cutting the transaction card and one or more other transaction cards from the composite.

28. The process of claim 16 , further comprising personalizing each card after cutting the card from the composite.

29. The process of claim 16 , further comprising forming a pocket extending from the opening and having a pocket bottom with a depth less than the thickness.

30. The process of claim 16 , wherein the embedded electronics comprises at least a printed circuit board and a battery.