Overmolded electronic components for transaction cards and methods of making thereof

1. A transaction card, comprising:

a first metal layer having an opening configured to receive a DI chip and at least a first aperture connected to the opening;

a second metal layer having a second aperture; and

at least one embedded electronic component between the first and second metal layers.

2. The transaction card of claim 1 , wherein the at least one electronic component comprises an antenna configured to inductively couple with the DI chip.

3. The transaction card of claim 1 , wherein the first aperture comprises a slit defined between a peripheral edge of the card and the opening.

4. The transaction card of claim 1 , comprising an insert in the second aperture in the second metal layer.

5. The transaction card of claim 1 , wherein the first layer, the second layer, and the at least one embedded component are laminated together.

6. The transaction card of claim 1 , wherein material from a lamination layer fills at least a portion of the at least one first aperture.

7. The transaction card of claim 6 , wherein the material from the lamination is transparent.

8. The transaction card of claim 7 , wherein one portion of the at least one first aperture contains the transparent material and at least another portion of the at least one first aperture contains non-transparent material.

9. The transaction card of claim 2 , wherein the antenna is disposed in a transparent window.

10. The transaction card of claim 5 , wherein the insert comprises a non-transparent material.

11. The transaction card of claim 10 , wherein the non-transparent material is disposed flush with a first surface of the first metal layer.

12. The transaction card of claim 10 , wherein the non-transparent material protrudes into the at least one first aperture.

13. The transaction card of claim 10 , wherein a different visual appearance of the non-transparent material relative to the body comprises a difference in color, texture, reflectance, opacity, and combinations thereof.

14. The transaction card of claim 4 , wherein the insert comprises a transparent material and a non-transparent material.

15. The transaction card of claim 4 , wherein the insert comprises a transparent material with decorative printed content.

16. The transaction card of claim 3 , wherein the slit is continuous and comprises a first portion filled with a first material and a second portion filled with a second material, wherein the second material is different from the first material.

17. The transaction card of claim 1 , wherein the first metal layer defines a front-facing surface and the second metal layer defines a back-facing surface.

18. The transaction card of claim 1 , wherein the at least one first aperture defines a first area that is less than a second area of the first metal layer.

19. A transaction card, comprising:

a first metal layer having an opening configured to receive a DI chip and at least a first aperture connected to the opening;

a second metal layer having a second aperture;

at least one embedded electronic component between the first and second metal layers; and

a transparent window formed within the first metal layer.

20. A method for manufacturing a transaction card, comprising:

providing a first metal layer having an opening and at least a first aperture connected to the opening;

providing a second metal layer having a second aperture;

molding a molding material about at least one electronic component, wherein the at least one electronic component comprises an antenna configured to inductively couple with a DI chip;

laminating the molded electronic component between the first and second metal layers; and

providing a transparent window formed in the first metal layer.

21. The method of claim 20 , further comprising inserting the DI chip into the opening.