Abstract: An electronic core for a metal card, such as a transaction card, having a metal core and a cured polymer top surface, is manufactured by a process in which a two-part polymer mixture is introduced to a reservoir holding the metal core in a process chamber, and then a partial vacuum followed by pressurization with inert gas are used to reduce the volume of voids in the partially-cured polymer mixture, followed by curing outside of the process chamber, and then the top surface is removed by a treatment operation, such as milling or etching, to form a reduced upper surface with less surface irregularities which is more substantially plan the original top surface.

Abstract: A metal surface card in which the metal surface is formed by a metal insert configured to be retained by interlocking shapes of the metal insert and molded polymer material sandwiched between the metal insert and an opposing surface of the card which is not metal.

Abstract: A process for placing a circuit array on a sheet having adhesive during a pick and place operation in which a vacuum is used during its placement to minimize air bubbles between the adhesive layer and the circuit array.

Abstract: Antenna and power control electrical circuits are configured for use with an initialization antenna for activating and personalizing an electronic core for electronic cards. When the antenna receives an RF signal, it turns on the power and redirects additional signals to a CPU. If the signal is validated, personalization information can be downloaded or self-diagnostic QC software can be activated; if a signal is not validated, the control circuits are reset. Once initialization is completed, the antenna control circuit is deactivated, and the power control circuit electrically connects the batter to the CPU.

Abstract: An interactive core for use in making electronic cards has rear and front adhesive layers which surround a stiffening spacer which has an interior opening in which electronic components (e.g., a PCB, battery and display) are located along with thermosetting polymeric material. A battery contained within the interior opening can be activated from an off state to an on state via use of an initialization antenna which can also be configured to allow a CPU to be customized for personal use.

Abstract: A sheet with registration holes cut in it is mounted to a surface of a pallet so that its registration holes are held taught by the outer diameter of bushings while an inner diameter pin shaft of the bushings is used by registration pins during multiple manufacturing process to provide registration of the sheet.

Abstract: An interactive core for use in making electronic cards has rear and front adhesive layers which surround a stiffening spacer which has an interior opening in which electronic components (e.g., a PCB, battery and display) are located along with thermosetting polymeric material. A battery contained within the interior opening can be activated from an off state to an on state via use of an initialization antenna which can also be configured to allow a CPU to be customized for personal use.

Abstract: A process for placing a circuit array on a sheet having adhesive during a pick and place operation in which a vacuum is used during its placement to minimize air bubbles between the adhesive layer and the circuit array.

Abstract: Improved battery packaging and constructions for batteries, particularly thin, flat-profile packaged batteries are provided. The battery packaging constructions may eliminate the need for soldering by providing current collector tabs coated by electrically conductive adhesive tape such as z-axis conductive tape and may provide support for current collector tabs and a regular battery perimeter by providing supportive battery packaging and/or frame materials. Better fabrication results, particularly when the batteries are used in smart cards, RFID tags, and medical devices.