CA2758361C - Contact smart cards having a document core, contactless smart cards including multi-layered structure, pet-based identification document, and methods of making same - Google Patents

Abstract

The present invention relates to identification documents and smart cards. In one implementation, we provide a smart identification document including a document core. The document core is printed and laminated. The laminated core is milled to create a cavity. An integrated circuitry module is provided in the cavity. In one implementation, the cavity includes an upper cavity and a lower cavity. A laminate layer houses the upper cavity while the lower cavity extends into the document core. The upper cavity's aperture exceeds the aperture of the lower cavity resulting in a ledge in the laminate layer. A portion of the module may rest on the ledge, while another portion of the module may extend into the lower cavity. In another implementation, we provide a contactless smart card including a multi-layered structure. The Structure includes a carrier layer including the smart card electronics. The carrier can be permeable (like a mesh or scrim) so that additional layers may be laminated into or through the carrier layer. A multi-layer structure provides a enhanced durability and helps protect the smart card electronics. In still another implementation, we provide a PET-based identification document. The PET-based document includes favorable durability and earth-friendly characteristics.

Description

CONTACT SMART CARDS HAVING A DOCUMENT CORE, CONTACTLESS SMART CARDS INCLUDING MULTI-LAYERED
STRUCTURE, PET-BASED IDENTIFICATION DOCUMENT, AND METHODS OF MAKING SAME
[001]
Technical Field [00021 The present invention relates generally to identification documents and smart cards.
Background and Summary [0003] Verifyinz one's -n-ue idmtify is an ever-incressin52-, problem.
Idmifify theft is rampant, and stolen identifies have even been used to facilitate terrorist attacks.
Computer networks and secure areas have been: breached vgith Traisapplopri-aed keys, passwords and codes. Convendonal solutions typically include a photo identification document having a photographic quality imsge of the license holder on the cloctunent protected frorn tunpering by one or more security feature. Another soladon. is the use of so-called "smart cards."
[0004] The term "smart card" as used herein is defined broadly to generally include a device that carries informstion. (The definition of a snaart card used in this applicafion is broad enough to include so-called radio ,frequency idmtification cards ¨ or RFD
cards.). Typically, a smart card includes a microprocessor (or electronic processing andkr memory circuitry embedded therein. The electonic circuitry is oftm packaged as a modrd.e. A mero_ory smart card stores infOrrrat.011 ira electronic memory circuits, wh_ne a processor smart card can manipplstP infonnadon stored in associated raemory. Of course a SZI2Mt card module can include both processing and memory circuity. A "contact' smart card commimicates via a physical contact interface. A
contact smart card is typically ingerted into a smart card reader, thereby making physical contact betweeri the interface and the reader. A "contactless" smart card may have an antenna thro-agh which sigaals are communicated, as shown. in U.S.
Patent No.
6,424,029. Thus, a con:tactless smart card may not need a physical interface.
Of corse, a smart card can include both a contact and contactless (e.g., mtenna and supporting circ-uity) interface. A smart card may be passive in that it lacks an internal power source. Power can be supplied through its interface, which enerj7es the smart card's internal circuits. Of course, there are smart cards that may include an internal power source. Further backuound for smart cards and smut card readers can be found, e.g., in U.S. Patent Nos. 5,721,781, 5,955,961, 6,000,607, 6,047,888, 6,193,163, 6,199,144, 6,202,932, 6,244514, 6,247,644, 6,257,486, and 6,485,319.
[00051 Smart cards are capable of pmforming a variety of functions, including ca.ilying data, rnsnipuladon or processing information and data, con-tolling access (e.g.;
by =Tying pass codes, biometric data, passwords, etc.), providing identifying_ infonnadon, holding biometic data, etc. Of come, this is not an exhaustive List of possible smart card functionality.
[00O6-1 A conventional smart card manufacturing process provides a blank card.
The blank is drilled, perhaps by a second. -rv-mdor or manufacturer. A..,anart card. chip is ipserted into a pre-drilled 131Prvk (U.S. Patent No. 6404,643 discloses a card with a.n integrated circuit. The integrated circuit is attached to a cad blank and is bonded by melt Bowing adhesive. The card blank can. have a pre-drilled cavity frith which the integrated circuit is placed, or may be the same size and shape as is the card blank and a space there between is filled with Pdhesive.) Often times the chip -911ed blank is passed to a third vendor or manufacturer who prints or elk" _rave....s the chip filled blank- The printing processes available at this stage are sometimes limited. In fact, printing is not always possible on both sides of the card ¨ due to the contact area presented by a smart card module. Even if a smart card is printed after embedding ari integrated circuit module, the prhidng rnsy nevert]aeless be vninerable to malicious attacks (e.g.., by chsncT:ing infounadon printed on the smart card).

[00071 We have found additional limitations that are associated with conventional sm.art cards. In the case of contact snaart cards, some of these problems include the smart card module popping off the card when flexed, flex stresses that darnage the smart card. module, and/or the card itself cracki.ng -with normal wear and tear.
[0008] Accordin gly, in one embodiment of the present invendon, we provide a contact smart card including a core layer. The core layer can include a synthetic paper ¨ offering flexibility for the contact smart card. Thus, the synthetic paper core may also help to reduce cracking often seen after normal wear and tear of conventional smart cards. The core layer is preferably preprinted, perhaps with personal information, prior to the insertion of a smart card module. We can print high quality irnges and text¨ on. both sides of the document, if ne.eded ¨ since the craart. card module is installed after printing. The print is preferably covered with a laminate to offer intrathon protection and wear-and-tear protection. A cavity is formed in the laminated stricture and integrated circuity is secured. in the cavity.
[0009] S0120.8 of our sm&rt card processes cart also be con-tolled by one entity, if desired, such as in a "central" issue (CI) program. Commercial systems for issuing ID
documents are of two maim types, namely so-called "central" issue (CI), and so-called "on-the-spot- or "over-the-co-rater" (OTC) issue. Of course, we envision that we will provide so-called "blank" docnments (e.g., document structures without printing and nafioia or with some pre-printing and/or some lamination) to over-the-counter (OTC) issuing stations.
[00101 Cental issue type ID documents are not immediately provided to the bearer, but a-re later issued to the bearer from a cental location. For example, in one type of CI
eronment, a bearer reports to. a docnment stafion where data is collected, the data is forwarded to a central location where the card is produced, and the card is forwarded to the bearer, often by mail. Another illustrative example of a CI assembling process occurs in a setting where a driver passes a driving test, but then receives her license in the mail from a CI facility a short time later. Still another illustrative example of a CI

WO 03/056499 Pet/USK/41320 asseanbling process occurs in a setting where a driver renews her license by mail or over the Internet, then receives a drivers license through the mail [00111 Centrally issued identification docp-rnents can be produced from c3iesily stored i-nformation and generally comprise a core material (also referred to as "s-ate"), such as paper or plastic, sandwiched between a plurality of layers of, e.g., clear plastic Ismi-nate, such as polyester or polycarbonate, to protect printed information (e.g., photographs, text, barcodes, biometic representations, security features, etc.) from wear, ex-posure to the elements and tampering. The materials used in -such CI
identification documents can offer the -ultimate in din-a.bility. In addiU.onõ
centrally issued digital identification documents generally offer a higher level of security than OTC identification documents because they offer the ability to pre-print the core of the central issue docpment with seetuity features such as "micro-printing", ultra-violet security features, security indicia and other features catte_atly -unique to centrally issued identification documents. Another security advantage with cent-ally issued documents is that the security features and/or secured msterials used to m_a_ke those features are centrally located, reducing the chances of loss, Migappropriaiion or theft (as compared to having secured rnsterials dispersed over a wide number of "on the spot"
locations).
[00121 . In addition, a CI assembling process can be more of a bolle process fseility, in which many cards are produced in a centralized facility, one after Pnotlier.
The CI
facility may, for example, process thousands of cards in a continuous mare-ter. Because the processing occurs in bulk, CI can have azi increase, in efficiency as corapared to some OTC processes, especially those OTC processes thst run. inteiiiittently.
Thus, CI
processes can sometimes have a lower cost per DD docn-nent, if a large volume of ID
documents is manufactured_ [00131 In contrast to CI id_entificadon d.ocurnents, over-the-counter ("OTC") identification docuraents are issued immediately to a bearer who is present at a docnment-issuing station. An OTC assembling process provides an ID document "on-the-spot." (An illustrative exs-nnie of an. OTC assez_nhling process is a Deparbue,nt of 1\-fotor Vehicles ("DMV") setting w.here a driver's license is issue...d to a person on the, spot, after a successful exam.). In some instances, the very natme of the OTC
assembling process results in small, sometimes compact, printing and card assemblers for printing the ID document [0014] In identification wad security applications, it is often desirable to increase the functionality of identi'ication documents. Accordingly, one aspect of the present invention my provide the look and/or feel of conventionsl identification docents while providing gmart card Brnctionslity. Ill one i-mplementation, we combine an image bearing identification card. with smart card functionality. We sometimes refer to these type of docnments as "smart identification docnments." Iri another implementation, we "upgrade" an identification document that may have already passed into circulation by providin a a smart card module within a pre-circulated M docm-n est.
P01_51 Another aspect of the present invention involves modification. of a synthetic = paper core-based identification OD) document to provide a smart card that includes integrated Circuitry (e.g., a semiconductor chip. and interface), laser, thermal transfer arid/or offset printed i-r1Pq.es (e.g., including photographic representations) and/or custorni7ed (or personsli7ed) text and data.
polo] . (In this document, the use of the teinis "identification document" and "ID
document" is intended to include at least sll types of TO docn---nents. Note that, for the purposes of this disclosure, the terms "document," "card," "badge" and "documentation" are used interchangeably. In addition, D documents are broadly defined herein and include (but are not limited to), documents, rnsnetic disks, credit cards, bsnk cards, phone cards, passports, driver's licenses, network access cards, employee badges, debit eards, security cards, visas, immigration documentation, national ID cards, citizenship. cards, social security cards and badges, certificates, identificatiori cards or documents, voter redsfratiori cards, police ID cards, border crossing cmrls, security clearmoe badges and cards, gun permits, badges, gift certificates or cards, membership. cards or badges, tags, CD's, consumer products, knobs, keyboards, electronic components, etc., or any other -suitable items or articles that may record infonnadon., images, andior other data, which -may be associated with a Emotion and/or an object or other entity to be identified.).
[0017] In addition, in this document, "identification" includes (but is not limited to) informPtion., decoration, and may other purpose for which an indicia can be placed upon Fri article in the article's raw, partially prepared, or final state. Also, instead. IUD
documents, our inventive techniques can be employed with product tags, product packPzing, business cards, bags, charts, maps, labels, etc., etc., particularly those items including an laminate or over-Ipminate structure. The tutu: lD document thus is -broadly defined herein to include these, tags, labels, packacias., cards, etc.
[0018] According to another aspect of the present invention, a smPrt identi-Fica.on document includes: a core layer including a first surface and a second surFAce; a first layer of a substantially tanspuent polymer p.djacently azi-anged on the first surface of the core layer; an aperture; and a module. The aperture includes a first section disposed in the first polymer layer, the first secdon including a ledge in the first polymer layer, and a second section disposed in at least the core layer. The module includes electronic circuitry, whertt.--in at least a first portion of the module is adjacently arranged with the ledge, and at least a section portiori of the module extends into at ?east soma of the_ second section of the aperture.
[0019] According to sfill another aspect of the. present invention, an identification docnment includes a core layer including a front side and aback side; printed indicia formed on at least the front side of the core layer; a first Ipminate layer secured with an adhesive to the back side of the core layer; a second 1,-Imiriate layer secured. with an adhesive to the front side of the core layer; a cavity disposed in the 'first IF:mi-iptP, the cavity extending through the first IFiminFete layer, adhesive and into the core layer; and electronic circuity disposed in the cavity.
[ono} According to yet another aspect of the invention a manufactuina method includes the steps of: providing a first laminoe and a second lamin.ate, the first lqinina...te comprisina a front surface and a back surface, and the second lpi-ni-tPte comprising a WO 03/056499 =

front surface and a back surface; adjacently arranjng an adhesive with the back surface of the first 1A-rninAte; adjacently arranging an adhesive with the back surface of the second laminate; providing a core having a top suria.' ce and a bottom surface;
lAminating the first lArninare, Adhesive, core, adhesive and seconci laminate to form a stuctre; machining a portion of the stact.rt; and providing an integrated circuity module in the machined portion of the structure, the interated circuitry module providing at least some si.tt card functionality.
[00211 Still another aspect of the present invention relates to a rniilin a tool for rniliing a polymer and a synthetic paper structure to receive a slnart card module. The tool includes: a fluted shaft having a first section and a second section; a first cutting edge having a first. bevel disposed on the first section; a second cutting edge having a second.
bevel disposed on. the second section, the fust and second cutting edges funning a fist axis; and wherein a non-cutting end of the first bevel and a non-cuttill2 end the second bevel forni a second axis which is rotated at a first angle in a ranee of 15-60 degrees from the first axis.
[0022] Yet another aspect of the present invention relates to a method of mil lin.g cavity in an identification document to receive a smart card module. The identification docment includes at least a IminAte layer ¨ document core .structure. The method includes provisli-tg a first cut in the lp-minate layer to create a rough upper cavity, the mud]. upper cavity inclu -ding a first aperture; providing a second cut to create a lower cavity, the lower cavity extending through the larniTtPte, layer into the docpment core, the lower cavity and the rough upper cavity being approxi-nRtely centered arotmd a common axis, wherein the aperture of the lower cavity is relativel-y smaller than the aperture of the rough upper cavity resulting in a shelf in the 1A-minate layer; and providing a third cut around the rough upper cavity to create a finished upper cavity, the fmiched upper cavity having An apertte which is larger than the apertat of the rough upper cavity, the finished upper cavity being approrhrtately centered around the common axis.

[00231 Sfill another aspect of the present invention includes an identification document including-: a first PET (polyethylene terephthal ate) fii-n including a top surface and a bottom surface; a second PET film including a top -surface and a bottom sinface; an i-uAge-receiving layer provided on the first PET film top surface;
and an adhesive layer in contact with the first PET -91m bottom surface and. the second PET
film top surface, the adhesive serving.; to secure the first PET filna and the second PET
film to one another.
[00241 Still another aspect of the present invention provides a method of raPicing a contactless smart identification docn--nent. Tiae method includes: provid_hlg a carrier layer including at least an antenna arid elect-on-lc circuitry, wherein the carrier comprises at least one permeable area; dllanping the ccatier layer between a first contact layer and a second contact layer, and then seeming the first contact layer And second contact layer to the carrier layer through at least one of heat and pressure so that at least a portion of 0.11C of the first contact layer and the second contact layer inigates into the earlier layer at the one permeable area; and providing first pnd second la-ninate layers over at least the first and second contact layers, respectively.
[0025] Further aspects, features and advantages of the present invention will become even more apparent with reference the following detPile,d description and the accompanying (171-wrings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a cross sectional view of an identification document including a document core.
[0027} FIG. 2A is a Lauss-secuonal view of the FIG. 1 doc=ent including a cavity provided therein to receive a -Rmart card module (e.g., a contact-type smart card module).
[0028] FIG. 2B is a cross-section-q1 view of the FIG. 2A doom-Pent including adhesive provided on a layer shelf.

[0029] FIG. 2C is a cruss-sectional view of the FIG. 2A document including a smut.
card module provided in the cavity.
[0030] FIG-. 3 is a'flow di. -a illustrating steps to rnmiufacture, e.g., a contact-type smart idenfificadon document according to one aspect of the present invention.
[0031] FIG. 4A is a cross-sectional view of the FIG. 1 document incluclilg an npper cavity provided in aim-Ili-nate layer.
[0032] FIG. 4B is a cross-sectional view of the FIG. 4A document includi-ng a lower cavity- extearliTig into a core layer.
[0033] FIG. 4C is a cross-sectional. view of the FIG. 4B document inclwiing a )9-nish cut of the upper cavity.
[0034] FIGS. SA-5F are diagrAms illustating a milling tool according to one aspect of the present invention.
[0035] FIG. 6 is a cross-sectional view of a contactless. smart identification-doctuneut accordLag to one implementation.
[0036] FIG. 7 is a cross-sectional view of mother implementation of a contactle,ss smart identification docnrnent [0037] 1,1G. 8 is a ca-uss-sectional view of still another implementadon of a contactiess small identification document.
[0038] FIG. 9 is a cross-sectional view of yet another implementation of a c.ontactless smart idendfication document.

WO 03;056499 PCTIUS02141320 [00391 FIG. 10 is a top view of a contactless smart identificadon document's carrier layer including an anten-la and inteErrated circuitry according- to one aspect of the present invention.
[0040] FIG. 11 is a cross-sectional view of a contactless "rn21't identificafion document according to pnother implementadon of the present invention.
[00411 FIG. 12 is a cross-sectional view of the FIG. 11 contactless s-nart identification document including over-la.mimtez.
[00421 FIG. 13 is a cross-sectional view of a Fnislhed over-the-counter identification document (conventionP1 art).
[00431 FIG. 14 is a cross-sectional view of a PET-based. idendficadon document according to one implementation.
[0044] FIG. 15 is cross-sectionpi view of another PET-based document according to still another implemeritadon_.
[00451 Of course, the drawings are not necessarily presented to scale, with emphasis rather being placed upon illustrsting the principles of the invention. In the drawings, lie reference numbers indicate lilce elements.
DETAILED DESCRIPTION OF THE INVENTION
[00461 The Detailed Description is divided into three sections for the, reader's convenience "Contact Smart Cards Including a Document Core," "Contactless Smart Cards Including Multi-layered Structure," and 'Manufacture of PET-B.a.sed.
Identification Document"). It should be appreciated, however, that elz.¨ments and fzictiori2lity disclosed Ea cue section can be readily combined with elE.-õments and WO 63/656499 PCDT.302/41320 fancEpn2lity found in another section. Therefore, the section headings should not be interpreted as liraifing the scope of the present invention.
Section 1: Contact Smart Cards including a Document Gore [00471 For purposes of illustration, the following section will generally proceed with reference to contact-type smart cards (which are sometimes interchangeably referred to as a "contact smeat ID document" or a "smart ID document"). A preferred contact-type smart lD document includes a multi-layered ID docu-neni including a document core and. fased or sectred polymer laminates. The multi-layered ID document is provided with integrated circuitry to facilitate processing molfor memory storage. It should be appreciated, however, that the present invention is not so limited.
Indeed, as those slolled in the art will appreciate, the inventive techniques can be applied to many . other structures formed in many different ways. For example, contactless smart card modules can. be suitably packaged, with such packages being disposed in a cavity created in a multi-layered docu-nent structure.
[0048] FIG. 1 is a cross-sectional view of an identification document 1 according to one aspect of the present invention. The identifica.don. (Li) document 1 is used as the foundation for a smart ID document. The ID document 1 preferably includes a core 10, and a generally transparent laminate 1.2. The DD d_ocUrnent will typically include a second IPTninate layer 14. Adhesive 11. and 13 is preferably used to help adhere the la-Twinate layers 12 and 14 to the core 10. (Instead of separate adhesive layers 11 and 13, the laminate 12 may be coated. with an adhesive or may include adhesive materials.) If iudicia (e.g., printed text, iniages, machine readable code, etc.) is provided on the core or la-ninate sm-face(s), the adhesive 11 and 13 is preferably ra-nsparent. A
Imirinfe structure can be cut to meet the dim msions specified for a particular identi-5cabon document, if needed.
[0049] Indicia (inte.-,Tchangeably used with "information") can be provided (e.g., scram printed, oals' et printed, gravure printed, thca.a.tal -tansferred, provided via ii-ior laser j printiriz., laser enaved, etc.) on the front Rndlor back surface of the core 10 or lr-rnipate 14/adhesive 1.3 prior to lamination. For example, the information mRy inclu.d_e variable information, which is informa-dorì that is unique to a cardholder (e.g., nem.- e, birth date, age, sex, weight, address, bioraetric infonnafion, photograph, and/or si2-_nature, etc.). The information m.ay also include so-called "fixed"
information.
Fixed i-nformation is generally thought of as that information which remaainP, constant frorn card to card, such as issuing agency information, seal, arid./or some types of security desis, etc. Additional infonnadon, e.g., optical variable devices, can be provided on the core 10, adhesive 11 and 13, or Thminqte layers 12 and 14.
(Reference maybe had to assignee's U.S. patent application no. 09/969,200, filed October

2, 2001, for even farther infon. nation regarding optical variable inicg and devices.).
Other sectaity features that ma_y be optionally presented on the sm%-st identification document include, e.g., ghost images, -microprinting, ultraviolet or h_-...r,Fared images, biometric info, ki tat-ion, etc We can optonaily provide a print receiver (e.g., an imsge-receiving layer) to help a core or laminste layer better receive printed or transferred in form.afion.
(For example, see the D2T2 receivers discussed in the presmt patent document and in U.S. Patent No. 6,066,594.).
[00501 Printed or engraved inforriaation may optionally include a so-called digital watermprk. Ditql watermarking is a process for modifying physical or electronic media to embed m.achhae-readable indicia (or code) into the raeslia. The media rrmy be modified such that the embedded code is imperceptible or nearly imperceptible to the user, yet may be detected through an automated detection process. In som.e, embodi-ments, the printed or engraved information identification document includes two or more digital watei_Larks. In other embodiments, a digital watemark is "fragile"
in friPt it is designed to. degrade or be lost upon copying and/or repro.
&acing.
[00511 Digital. waterriarking systems typically have two pri¨mr3r components:
an encoder that embeds the dig,ital watennark in host media, and a decoder that detects and reads the embedded (digital wat=aiark from a si7al suspected of coutainirkg a thgital watc.ti.inPrk 'The encoder embeds a clital watermk by aIteri3ag the host media sipal.
(E.g., the -encoder can mq1ce czlight alterations to a graphic, background pat= or photograph that is to be printed. on an idendfication document. The alterations may be =

to pixel values, DCT coefficients corresponding to the host media sip2.1, ansform domain representations of the host media siDaals, etc., etc.). The reading corvonent analyzes a suspt signal to detect whether a digital watermark is present. In applications where the digital. watermark encodes infornadon (e.g., as a payload or message bits), the reader extracts this information 'from the detected digital 'watermark.
The reading component ca.n be hosted. on a wide variety of tethered or wireless reader devices, 'from conventional PC-connected ca-rneras and co_nputers to fully mobile readers with built-in displays, etc. By imaoing.-, a watermarked. surface of an identification docnment, the watermark information can be read and decoded by a reader.
[00521 Several particular digital watermarldng techniques have been developed_ The reader is presumed to be familiar with the literature in this field. Some techniques for embedding and detecting imperceptible watermarks in media simals are detailed.
in the assignee's co-pending U.S. Patent Application No. 09/503,881, U.S. Patent No.
6,122,403 and PCT patent application PCT/US02/20832.
[00531 (ateria1 types are now provided by way of example only. Of course, there are many other materials that may be suitably interchanGed with some aspects of the present invention_ Rent-ming to FIG. 1, the core 10 material can include a synthetic such as TESLLNT, other synthetic materials, polymer, composite, and/or polyp:lean, etc.
T.BSIINI is a s-.-ynthetic paper sold by PPG Industiles, Inc., One PPG Place, Pittsburgh, PA 15272 USA. iESLIN can be provided in sheets, with multiple cores taken from each TESLIT.st. sheet. The laminate (sometimes called an "over laminate") may include (but is not limited_ to) film and sheet products. Laminates usable with at least some embodiments of the invend.ora include those which contain substantially transparent polymers and/or substtially transparent adhesives, or which have subsimadally fransparent polymers and/or substantially transparent Adhesives as a part of their sittiGtare, e.g., as an extruded feature. In some of the eraibodianents of the present invention, the term "laminate" may include both the la-ninate and adhesive layers (e.g., layers 12 p.rg-1 1f), e.g., in 'FIGS. 1-2C. Examples of usable laminates in.clud_e at least polyester, polycarbonate, polystyrene, cellulose ester, polyolatin, polysulfone, or polyarnide, etc. Ls-minPies can be made using either an o-norphous or bia_xiany oriented polymer as well. A laminate can. comprise a plurality of separate IsminRte layers, for example a boundary layer and/or A film layer. Our m.ost preferred larningte, however, is a polycarbonate. Various innination processes are disclosed in assiziee's U.S. Patent Nos. 5,783,024, 6,007,660, 6066594, and 6,159,327.
Othe,r1..ination processes are disclosed, e.g., in U.S. patent Nos. 6,283,188 and 6,003,581.) [00541 (The degree of tansparency of a Iprninpte can, for exqmple, be dictated by the information contzirked on the core layer, the particular colors and/or security feat-in-es used, etc. The thickness of the laminRte layers is not orifice, although in some .
embodiments it may be preferred that the thickness of alpminate layer be about rnir; (where 1 mil is about 25 pm). Lp-s-zination of any lamina.te layer(s) to any other layer of material (e.g., a core layer) can be accomplished using a convmfional 1Prnination process, and such processes are well knovvn to those skilled in the production of articles such as identification. documents. Of course, the types and structures of the lsmi-nstes described herein are provided only by way of example, those skilled in. the art wiil appreciated that Tiny riifFerent types of IF-ninstes are usable in accordance with the invention.. The material(s) from which a 1,4minate is made may be thqnsparent, but need not be. Laminates also includes sectrity laminPtes, such as a t-ansparent isminste material with proprietary security technology features and processes, which protects doorrnents of value froru coterfeffiiig, data alteration, photo substitution, duplication (including color photocop3rin.g), and s;.ifulation by use of materials and technologies that are commonly available. L2rninates also can include thenuosetting.-. materials, such as epoxy.). Suitable 1FrminFit materials can be rearlily obtained, e.g., from GE Plastics, headquartered in. Pittsfield, MA USA.
Lsmiristes cari be even. provided in roll form, e.g., 1000 ffiroll (e.g., about 21 cards/ft).) [00551 (One adhesive material (e.g., layers 11 and 13 in FIG. 1) Can include, e.g., KR:TY as provided by Transilva-ap, headquatered in Frqrfklin Park, Illinois USA. The adhesive m.ay also be provid_ed as a lami.nate layer or coated. onto the 1P-rninate or lprninate rolls. Other adhesives us=ible in accordPnce with some embocifments of the, invention include, polyester, polyester urethane, polyether urethane, polyolefn, andlor hot rnelt or ultraviolet or thermally cured adhesive, thermoplastics, etc. The mul.d.-layered structure is formed during a IminRlion process, in which adjusanents to the processing time, tumperature and pressure can be varied to optimi7e laminsuon.) [00561 Dimensions of an D document will vary according to specified design requirements. For opmple, applicable International OraPnization for Stal-idpri-Tivation.
(ISO) specificadons for identification docum.ents may specify required dimensions.
Wi __ specified di-ne.nsions there is some di--nension. play. In one implementation, we provide a core inc11rìirtg an 4-20 inil depth, adhesives with a 2-7 mil depth, and lami-late layers ranging from 3-15 mils. Our most preferred implementation provides a 12 mil __ back lamirtate, a 2 mil back adhesive, a 12 mil core, a 9 mil front adhesive and a mil front laminate.
[00571 In some implementations we provide a matte finish on a top surface of the back laminate.. layer. The matte finicll helps to feed the lsminate layer if provided in roll form.. The matte -finish may also provide a tactile security feature, as an inspector can feel the text-are of the card (e.g., a matted finish) to dete=ine if tb.e card is [00581 With reference to FIG. 2A, a cavity or well 20 is provided (e.g., macbi-ned, Glit or laser etched, etc.) in the FIG. 1. ID document 1. We interchangeably use the tenns "cavity" qnd "well" in this docnment. The well 20 provides a housing or receptacle for a smart cutl integrated circuit module (hereafter SOMDtarteS
referred to a "module" or as "smart card module"). The shape and dimensions of the well 20 vv-ill vary according to the shape and dimensions of a selected smart card module that is to be inserted into the well 20. For disc-assiori purposes we have chosen to illustrate the present invention with respect to the Hitachi AE 45C smart card chip module, as provided byI--Litachi, located in Maidenhead, Berkshire,IJK, and which.
provides 32K
bytes of memory. A multi-application chip operating system, e.g., MULTOS or any other suitable chip operating s-ystem, can he used to control the operation of the smart card module. MULTOS caxi be obtained, e.g., through Mosso), Ltd in London NO 03/056499 PC1fCS02141320 England. (We note that riimensions of the Hitachi AB 45C module are analogous to the Atriel 1608 Module, which, like other smart card modules, can be suitably interchanged with the Hitachi AE 45C module.). Our chip selection will naturally dictate some of the shapes and dimensions discussed below. It should be appreciated, however, that the present invention is not so limited. Indeed, some aspects of the present invention anticipate the cooperatiori with may rliffermt smart card modules, and conesponelia)g cavity 20 shapes and depths. For example, iEi one implementation;
i-tstead of the rectangular shaped cavity 20 as illustrated in FIG. 2A, we provide an oval shaped cavity. The oval shaped cavity cooperates, e.g., with an oval shaped smart card module (e.g., Atnel's model no. AT8SSC1608-090T-00 ¨ headquartered in San Jose, CA USA). Of course there are many other cavity and module shapes and sizes ti-tPt will fall within the scope of the present invention..
[00591 Returning to Fia 2A, cavity 20 may include an upper chamber (or cavity) 20a and a lower chamber (or cavity) 20b. The depth D of the upper chamber 20a is geracaally dependent on a corresponding d.epth of the smart card naodule. We have found that it is generally preferable to seat the smart card module in the cavity 20 so that the module's interface is about flush with the outer surface of larrainate 12, although the module's contact interface can slightly protrude above (or below) the laminate 12 surface. This seating arra-agement helps to prevent the sm.at card module from catching on objects, Which may undesirably unseat the module from, the cavity 20.
The upper chamber 20a, which is adjacently arranged to the lower chamber 20b, preferably includes a relatively larger aperture tham that of the lower chamber 20b. The apertare differences between the lower cavity 20b and the Tipper cavity 20a results in a allelf 22. Vare have found that it is preferably (but not required) to provide the shelf 22 in the laminate- layer 12, while* allowing safficient laminate shelf depth d, since a smart card module's adhesion (e.g., via adhesive) to the laminate layer 12 is generally superior thPn a module's adhesion (e.cf via Pcfhesive) to adhesive layer 11 or core layer 10. lithe depth d is too small, the shelf 22 may pull up and away -from the arlhesive 11 and/or core 10 layerS. In some cases we have found that too small of a depth d results in the shelf 22 and adhesive 11 together pulling up and away from the core 10.
The depth d in our most preferred implementafioai is about 2 mils. Of course this preferred depth d may vary as stracture layer depths or module dimensions vary.
[00601 If using the M document 1 as shown in FIG. I, the lower cavity 20b preferably extends through, e.g., the larninate 12 and PrilleSiVe 10, and.
into the core 10.
A depth D+ of the lower cavity 20b is generally dependent on the vertical depth of the smPri.: card module. While not necessary to practice the present inverthon, we can provide enough depth D so that the bottom of the mart card3nodule will "float" in the well or otherwise liot contact the bottom. B of the vv-eLi 20 when the lD, card is at rest (see FIG. 2C). This floating arrangement provides som.ewhat of a Gil .hion.
for the smart card module ¨ allowing the card to flex without causing -tmdue sixess on the bottom of the smart card m.odule. (We note that some thought should be given to the depth D pf a well, since if the well is too deep, a card assembler risks having the bottom surface of the smart card module show through the renv-i-ning core depth ¨ resulting in unwanted discoloration when viewed frona the front of the card.) In our most preferred implementationõ the ID+ deptia extends about 10 miis into the core layer. (Of course, thirz, depth can. be altered accor6ing to layer dimension.s and sn-. dart cmd module used, etc.). In other implementations, the bottorn r4-idlor sides of a smart card module contact the bottom. B and/or or sides, respectively, of the well 20, perhaps through an adhesive.
[0061] We preferably provide an adhesive to help secure a sm.art card module 26 in the cavity 20. There are several. options for providing adhesive. With reference to FIG. -2B, we can provide an adhesive 24 directly onto shelf 22, e.g., through injection or spot adhesives. Alternatively, the -smart card. module can be coated with an affiesive on a side that is to be adjacently positioned with shelf 22 (We note that a gmart JD
docn-rnent maau-facturing method can be automated. In such cases, the smart card modules can be provided in roll form, e.g., one reel including about 7,500 chips.
Adhesive (e.g-., cyanoacrylate epoxy from. Henkel of A_merica.., iri Gulph Pennsylvania USA) or a roll of glue tape (e.g., Tesa RAF 8410 HS or Tesa BD.P.

from Tesa Tans, Lac. in Charlotte, NC USA) cm be applied to the bottoaai side of the chip roll. Assembling m2chines provide by, e.g., Mullibauer, headquartered in Radius, Germariy, ca.n be used for final assembly. Such an automate urocess may -1 8-.
proceed by printing a card, laminating, cutting and verifying dimensions and printed information, and then milling, implsnting a smart card module nnd then encoding or initis1i7ing the smart card modul.. Testing can be performed. to detect a bad smart card module, etc.). In an implementation without shelf 22, we coat the sides and/or bottorìi of a smart card module with adhesive, and/or piovide adhesive to a cavity and then insert the module.
[00621 A smart ID docoment results once the integrated circuitry module is secured in a cavity of an D document (FIG. 2C). A smart card module can be optionally progamrned to store relevant infomation such as information printi. on the docnment, biometic information, account information., cryptographic hashes or other algorithmic .
represention of data, passwords, etc. One prouunmer example is a computerized mart card Personahzer, e.g., as provided by Miihibauer of Germany, which enters commands or data into the smart card module. Other prous-mniers are provided, e.g., -from Hitachi and Atmel, -f-rtorig rnsny others. Information stored in the smart card circuity is optimally cross-correlated with. .M.formafion printed 01ra the smart card. This cross-correlation can be checked to verify authenticity of the doconent or stored information. Or if a digital waterrastic is provided on the docom out, a watermark payload can be cross-correlated with information stored in the smart card's memory circuitry. A cross-correlation of the watermark information and the, module's stored information can. be analyzed to deterudne authenticity of the identification document.
[00631 FIG. 3 is a flow diagram ilhastibting the steps to manufacture a contact smart card according to one implementation_ A document core or substrate is provided (step S30). The document s-ohstate (or sometimes a lominate/adhesive layer) is printed (step S32), e.g., to include personsli7ed or variable im'ormation. If printing on an. inner ls-n-inate or adhesive layer, the pfMting may be reversed so it appears properly oriented when viewed from the outer surface of the, Is-rtinate or adhesive layer. The printing raay also include security pattc,--r-_as and desigas, digital wateitharks, -m.d may also include optical variable devices, such as those prov.i.ded with optical.
variable irk' A
photograph may be included in the \-,ariable informatior_,. Prinr- u-g-options are widespre743 and may include, a., offset printincr_, screen piiinting-, laser or ink jet printing, laser engraving, thermal transfer, etc. An image-receiving layer can also be used, e.g., to better facilitate the reception of the information. The printed substrate is preferably laminated (step 34). The laminaon process may involve adhesives or adhesive layers, but the present invention is not so limited. The laminate structire optionally may be cut to desired specifications (step not shown), if needed. A
cavity or well is provided in the laminated, printed core (step S36). The cavity can be machined, milled, drilled, cut, etched (laser or chemical), etc. The cavity is preferably sized to accommodate a corresponding smart card naoduJe. In some implementations, the cavity extends into the core. The corresponding smart card module is secured in the cavity (step S38). While this method is anticipated to be most suited for contact-type smart card, we anticipate that some contactless-type smart card modules can be packaged such that they may also be provided in a cavity, e.g., as created with reference to FIGS.
2A-3.
Milling Operation (Example) [0064] FIGS. 4A-4C are cross sectional diagrams illustrating the methodology behind one milling implementation of the present invention_ A cavity is milled to receive a smart card module. We note that the illustrated method is but one of many methods = that can be used to mill or machine out a cavity in an ID document.
[00651 We start our milling discussion by returning to FIG. 1. .1G. 1 illustrates a multi-layered identification doenment including a core and laminates. We resli7ed that the material used for the laminate (e.g., polycarbonates) and core (e.g., a synthetic like TESLIN) was susceptible to tearing or leaving burrs when cut. The illustrated milli-ng technique (FIGS. 4A-4C) optimizes a milling operation to eliminate burrs in the multi-material cavity so that a smart card module can be securely mounted therein.
[0066] A milling (or machining or etching) tool contacts the back laminate 12 and machines amps-h. upper cavity 20a (see "Rough Cut" represented with dotted lines in.
FIG. 4A). The machining tool then (preferably after re-centering or realigning according to a reference or start position, or common axis) contacts the laminate at the bottom of the rough upper cavity to machine out the lower cavity 20b (see FIG.
4B).

We then pass the machini-ig tool back through the upper cavity (preferably after re-centering or realigning according to a ref.R.--dice or start position, or com¨ton axis) to shave or finish the upper cavity (see FIG. 4C). FIG. 4C illustrate the finish cut in relation to the original rough cut (dotted lines). An advantage of the -5-nish pass is to clean up any rough edges or burrs left from the rough cut. The 'mish pass can be subtle, e.g., slightly expanding the upper cavity 20a --while clemiir g up debris and rough edges. (In our prefeued implementation, the 'Trish pass comprises about a .001 mil cut.) Table 1, below, illustrates softmare, code that can be used to automate such a rrìiling process. The code is written so as to operate a Ninhlbauer cuttinu station, e.g., through a user intmface (e.g., a text editor or 07-aphical user interface) such as provided by Galli odon Control, Jnc. (Muhlbauer is headquartered in Roding, Germany, while Motion Confrol, Inc. is headquartered in Rocklin, CA USA.). Of course., the dimensions and instructions as illustrated in the Table 1 soilprare code can be changed accord'ing to need, card dhnensions, module dimensions, card mpi-prials used, cutting station pncl interface, et,-.
Table 1 #F30 1 Program Name 1 CRADIUS =1.8 POSX-15.1 !Defines center position for cavitv on card POSY=23.89 POSZ=0.0 #MOVXYZ
POSZ=Ø18 ! Surface ruff cut - LEAVE .0015" FOR Finish cut!
POS1Z=0.18 LENGTHX=12.9 1 LEKVE about .010u FOR CLEXK-UP
wTyPriv.11.6 .
RADIUS=2.3 LTS#RECT ling Instruction PR, -6000 ! Re-cuter over cavity 1 EGY

POSZ=0.47 I T.owan- Cavity final cut 1 POS1Z=0.47 LTMGTHX=8.4 WO 031056499 PCLITS02,(41320 WIDTHY=3.7 RADIUS=1.3 JS #RECT I Milling instruction PR ,-5000 Re-center for finish cut !
3Gv AMY
1:)OcZ=0.91 Fi ni sh Cut =
PCS1Z=0.21 LENGTH=13.4 WIDTH7=12.1 1 RADIUS=2.3 JS #RECT ! Milling Instruction POSX=15.1 I Return Tool to a home position !
POSY=23.89 POSZ=0.0 LTS #WAITPOS
ENT;
[0067} In an alternative iniTlementadon, we make a rough cut for the lower cavity 20b, and then follow-up with finish cut for the lower cavity 2012. In other izaplementations, we make one cut for the upper cavity 20a, and one cat for the lower cavity 20b. In still Rather impleraentPtions, we provide a first cavity including the lower cavity 20b, and then expand the first cavity to includes the final upper cavity 20a.
Debris ca.n be evacuated from the cavity 20 th-o. -ugh pressurized air or vacuuming., etc.
Millino Tool (Example) [00681 FIG. 5A-5D. are diagrA-ns of a milling tool that can be used to -mill a cavity in an D document. It should be appreciated that this is but one of many tools that can be used to provide a cavity in an. iden.tificadon document. In some cases, a laser or cher_r_lical process is used to create a cavity. In other implementations, conventional tools or cutters. are used to machine or cut a cavity in an identification document. . It will also be appreciated that vv-bile specific dimensions (in ___ iiii-meters) are provided in the FIG. 5 representations, the present invention is not so limited_ Indeed the dimensions can be chanzed in many respects without deviating from the scope of this aspect of the present invention.

-?9-[00691 With reference to FIGS. 5A and 5B, the cuffing tool 50 prefelably includes a shaft 51 having a Erst 52 and second 54 section. The shqft 51 can be fluted as shown in the figures. Therst section 52 includes a Ãrst cutting edge 52a and the second section 54 includes a second cutting edge 54a. Each of the cuffina edges 52a and 54a can be off-centered (see OC/ and 0C2 in FIG. 5A). Off-centering the cutting edges helps to provide an aggressive cutting tool, e.g., by increasing the tool's angle of attack (e.g., the angle at which a cuffing edge encounters material to cut). A face (or surface) of each of the first and second cutting edges 52a and 54a is preferably beveled or tapered_ The taper helps to ensure that the cutting edge is opfrmqily presented to the document ma:i-erial. While the FIG. 5 representations may suggest a 15-degree bevel, we anticipate acceptable cuts with a tool includina a bevel in a range of about 5-degrees. As shown in FIGS. 5A and 5B, a relief-56 can be provided for each of the cuffing edges. The relief is another mechanism to help present the cuitinEY, edge to the material in a favorable manner. While the figures suggest a 45-degree relief, we anticipate fh,qt a relief in the range of about 30-60 deo-reas will provide acceptable results.
[00701 One advantage of this type of tool is that its configuration allows for a carving type cutting moon, in 00121PaiSOn to conventional tools that pro-vide more of a scrapping or tearing motion. A carving motion allows for a clean cut, e.g., for shelf 22.
A clean shelf allows for a better bonding stia_race with an adhesive.
[00711 Other features and advantages of this cutting tool are readily discernable, ftom further exPrinination of the drawings, including FIGS. 5C-5F.
Inventive Combinations [0072] Iri addition to the inveadve aspects detailed above and in the cliTims, some of the inventive, combinations with respect to (e.g., contact-type) smart D
documents include the following:
[00731, _A_n identification_ doormerit coraprisina:
a cora layer includina a front side and a back side;

WO 031056499 PCl/US02/41320 printed formed on at least the front side of the core layer;
a hIrst laminate layer secured with an adhesive to the back side of the core layer;
a secondlp--ninate layer secured with an adhesive to the front side of the,' core layer;
a cavity disposed in the first larlinPte, the cavity extending through the first laminate, layer, adhesive and into the core layer; and electonic circuitry disposed in the cavity.
[00741 A1. The identification docn-nent of combination A wherein the cavity comprises an upper cavity and a lower cavity, an aperture of the upper cavity being relatively larger fh an an aperture of the lower cavity so as to result in a shelf, wherein the electpaic circuitry is packaged and a pordon of the package is adjacently arranged on the shelf.
[00751 A2. The identificadon document of combinaf4on Ai, wherein a pordon of the package floats in the lower cavity.
[00761 .A3. The idemdficadon d.ocnment of combination Al, wherein the lower cavity includes a floor in the core layer, and wherein a portion of the package extends into the lower cavity but does not contact the floor when the identification document is at rest 100771 B. A manufactri_nr..x. method comprising the steps of:
providing a first 1P-nirlate and a second larninste, the first laminate comprising a front surface and a back surface, and the second tarni-nPte comprising a front surface and a back surface;
adjacently arranQi-ng an adhesive with the back si.L.Tface, of the ffrst laminate;
adjacently auezigiric, pn adhesive with the back surface of the second laminate;
provichhe a core having top surface and a bottom strf-.ace;
IR----rinating the first laminate, Pribesive, core, adhesive and second lf-rninpte to -Form a structure;
machinin a a pardon of the structure; and WO 03/0.56499 PCTIES02/41320 providing an interate-.4 circuity module in the machined portion of the structure, the integated circuitry module providing at least some smart card functionality.
[00781 Bl. The method of combination B, further comprising a step of printing the core prior to said larninating step.
[00791 B2. The method of combinafion Bl, wherein the printing comprises at least one of a photogaph, name, birth date, social security unrnber, signature and identi-Fcation mnaber.
[00801 B3. The m_ethod of combination Bl, wherein the printing comprises at least one of: offset ink' s, process iTacc, thermal tangfer, laser xerography and laser printer toners.
[00811 B4. The method of combination B1, further comprising the step of cutting the stuctue into the chap,' of an idenfificalion card.
po821 B5. The method of combination B, wherein the core comprises a-sheet of [0083] B6. The method of combination. B. wherein the at least some smart card iimcfionality comprises at least one of data carrier, data manipulation., access control, identification. verification Mometic carrier and data processing.
[00841 B7. The method of combination Bl, wherein the printing comprises steganogaphic indicia.
mo851 B8. The method of combination B7, Therein the steganomphic inthcia comprises a digital watermark_ [00861 39. The method of combination B8, yvherein the digital \vat...51=k comprises a fra6.1e watermark.
[00871 310. The method of combination B8, wherein the integrated circuitry module comprises information stored therein, and wherein the information corresponds to the digital watermark for cross-correlation..
[0088] B11. An identhicatiori document made according to any one of the combinations sot forth in B ¨ B10.
p0891 C. A msTrafacturin.g method comprising the steps of:
provirlip....9.-. a first1pminpte and a second laminate, the first 1-rninPte comprising a front surface and a back surface, and the second lprriiripte comprising a front surface and. a back surface;
providing a core having top surface and a bottom surrare;
laminating the first 1sTriinate, secon.d 1FirinPte and core to foi t a s'ancture, the stuctare comprising the back surface of the first Iprii-1,,te in contact with the top surface of the core and the back surface of the second la-frii-mte in contact with the bottom. -surface of the core;
Triiii-ng a cavity through the first Ipminpite and into the core for Mcgintz an inte.grated circuity module; and providing an intea.ted circuitry moaile in the cavity, the integated circuity module providing at least some smart card finction21.ity.
[0090] Cl. The method of combination. C, thither (.3ornprising the step of printing the core or second 1-ii-ate prior to said 1P-rriinaiing sten.
[00911 C2. The method of combination C. wherein the core comprises a silica-h_qled polyolefn.
[0092j C3.. '.The method of oombination C, wh.c--zein the core comprises a s-y-nthetic paper.

[0093] C4. The method of combination C, wherein each of the. first laminate and second lr.-rninste comprise an adhesive layer, the adhesive layers being arranged between the first laminate and the core and second Isminste and the core, resnecuvely.
[00941 C5. The method of cornbinaton. C4, wherein the adhesive comprises a thermoplastic adhesive.
[00951 C6. The method of combination C, wherein at least one of the first laminate and the second ls-mi-tate comprises a sectrity feature.
[0096-1 C7. An identificatioxi document made according to combinadon C.
[00971 C. I-sin identification document made according to com.binstion C4.
[0098] C9. The method of combination C, wherein said -rn filing step creates a shelf in the first laminate layer, and wherein said providing an integrated circuitry module in the cavity stet) provides the module to be adjacently arranged on the shelf.
[00991 Cl(). The m_ethod of combination C9, whin at least a portion of the mod_ule extends into the core la-yer.
[0100] CI I. The method of combination C wherein the mod-ale portion that extends into the core layer does not ex-tend to a bottom of the cavity.
piou D. A mmurfacturing method comprising the steps of:
providing a first Isminate and a second is-ni-nate, the first laminate comprising a front s-arface and a back surface, and the second lam-haRte comprising a fl-ont surface and a back surface;
coating the back surface of the first Thrni-mte with adhesive;
coating the back surface of the second 1n2te with adhesive;
providing a core having top surface, antd a bottom. surface;

1Pnanng the first lanii-nate, second larTinate and core to form a AL
acture, the structure comprising the .adhesively coated back surface of the first laminate in contact with the top surface of the core and the c.rhesively coated back surface of the second 1P-ninate in contact with the bottom surfac-e of the core;
ma,-hining a portion of the AL uctm; and providing an integated circuity module in the machinai portion of the structure,, the intePzated circuitry module providing at least some smart card functionality.
[01021 Dl. A document made according to the method of combir ari on D.
[1o3] E. A matoufacturing method comprising the steps of:
providing a first la-ninaLte and a second laminate, the first laminate comprising a ont surface and a back surface, and the second arnirrte comprising a front surface and a back surface;
providing a core having top surface and a bottom staface;
1R-11-hating the first lainir ate, second laniinate and_ core to forna a structure, the AL __ uoture comprising the back surface of the first larninate in contact with the top surface of the core and the back surface of the second laminate in oontact -with the bottom surface of the core; and providing an integrated circuitry module in the AL _____________ acture, the integLated circuity module providing at least some smart card functionality.
[01041 El. A document made according to the method of combinafion E.
[01051 F. A method of milling a cavity in an. identificauon document to receive a smart card module, the idencation doon-nent comprising at least a 1iiinate layer ¨
document core sandwich stractue, said method comprising:
providing a first cut in the lr-m-iinate., layer to create, a rough upper cavity, the rough upper cavity including a first aptaiure;
providing a second cut to create a lower cavity, the lower cavity extending through the laminf--,th layer irto the document core, the lower cavity anT the rough upper =

cavity being approximately centered arornd a common axis,. wherein the aperture of the lower cavity is relatively smaller than the apertare of the rough upper cavity resulting in a shelf in the isTninate layer; and provie,ing a third cut around the rough upper cavity to create a flnighed upper cavity, the ished upper cavity- having an ape' ________________ au-e -wlich is larger than the apiiare of the rough upper cavity, the finished upper cavity being approximatel-y centered on the comnaon axis.
[lots] Fl. The method of combination F, wherein the, la-ninPte layer comprises an adhesive, so that the sandwich structure comprises a laminate ¨ aa..esive doctr-lent core structure.
[0/071 F2. The method of combination F1, wherein the shelf is provided in ls-ninqe [01081 F3. The method of combination F2, wherein the dom.: _ne,nt comprises document-hold.er speci-5c printing thereon.
[01091 F4. The method of eombination F, wherein the lq-rninate layer comprises a polymer and the document core comprises a synthetic paper.
[011(11 F5. The method of combination P4, whereia the synthetic paper comprises l'EST
___ Ti.
Mini F6. An identification document made according to any one of the methods set forth in combinations F -[01121 G. A contact smart card comprising:
a core layer inclurling a top surface and a back surface;
a fixstlate, layer adjacently secured to the., top surface, core layer;
a second ipTrinate layer adjacently secured to hack surface of the core layer;

printed indicia provided either on the top surface of the core layer or on a sTaface of the first 1P-ni-nate, layer that is to be secured to the top surface of the core, the indicia com.prising at least some iT-1-FormPdoii that is unique to a bearer of the contact srrtsrt card;
a well disposed in at least the second lprni-riate layer; and an integrated circuitry module provided in the well, the module includi--Ig a contact surface.
[0113] Gl. The contact smart card of combination G., wherein the well includes a shelf-in the ipm-i-nAte layer and the well extends into the core layer, and wherein at least a first portion of the module is adjacently arranged on the shelf and a second portion of the module exten.ds into the core layer.
[0114] G2. The contact smart card of combii72don G whereiri the informaliou compdse.s a photographic representation of the bearer.
[0115] H. Arrillirig tool for milling a polymer and 2. synthetic paper stacture for receiving a =at card raodula coniprising:
-Lluted shaft having- a first section and a second section;
a first cutting edge having a first bevel. disposal on the first section;
a second cuttiiig edge having a second bevel disposed on the second section, the h.-rst and second cutting edges forming a first axis; P-nd wherein a non-cutting end of the 'first bevel and a non-c-: irting end the second bevel form a second axis which is rotated at a first angle in a range of 15-60 degrees fr0121 the, ast axis.
[01161 111. The milli-tg tool of combinado-n. H, wherein the first bevel is tapered in a range of 5 and 45 degrees.
[0117] H2. The milling tool of combinadon H, viherein the first bevel is tVered at an Pi-kale of 15 degrees.
-[01181 H3. The milling tool of combination H, wherein the second bevel is tapered in a maze of 5 and 45 degrees.
[01191 E14. The milling tool of combination. H3, wherein the second bevel is tapered at an angle of 15 degrees.
[01201 H5. The rnillng tool of combination 113 wherein the first angle comprises 45 degrees.
Section 2: Contactiess Smart Cards including Multi-layered Stricture [01211 The following section primarily focuses on contactless mart cards.
However, it should be appreciated that our inventive techniques can be extended to inclu&
contact smart card and other ideadfication documents as well. A contactless smart card can be, generalized as a card including integrated electronic circuit--y.
Unlike a c,ontar-t-type smart card, where the integrated electronic circuity communicates via a physical contact inter-face, a contactless smart rard communicates (e.g., transferslreceives) data via ara antenna or transceiver stactare. The antenna (or transceiver) is connected to the integrated circuity. A contactless nart card_ may include an intemal power source to energize its electronic circuitry-. Alteinafively, the integrated circuiny can be energized through elecfromapetic energy received through the antenna (or other transceiver structure). The intv4rated circuitry can include data processing eh-cud* for processing - or marripulating data or software instructions, and/or memory circuity for data storage..
(Of course, the circuitry can include other components such as a clock generator, sy-steni bus structure, and b-affers, etc., etc.).
[01221 Some contactless smart cards have here-,tofore bee,a ffiliated with their fare share of -problems One problem is _protecting a contact between the antenna and the integrated circuity.. Communication ability of a contactles,s smart card vy-ill be lost or h.arape,red if the, contact between an. antenna and circuity is severed.
Protecting tbis WO 03/056499 Per/C-92141320 connection becomes a chore, since smart cards are often -subjected to on.erous stresses and flexing_ An associated problem with conventional smart cards is longe-vity. We have found that conventional contactless smart cards crack, dearade, andJor fail to oPerate as anticipated. We overcome some or all of these drawbacks in one implementation of an inventive contactless sr-tart card.
[01231 Another implementation of contactless sruart cards combines a contactless smart card with the ben.efits of an identification docrr-nent. Some idencation document benefits -nay include (but are not limited to): photographic representations, personalized info-ruadon, security indicia, over-1,minate layers, etc., etc.
[01.241 In another implementation of a contactless smart card, we provide a multi-layered card structine that provides the benefits of a smart card with the durability and flexibility of a multi-layer st-adare. Multi-layers may also provide protection from unwanted rad.; adon, e.g., ultraviolet radiation, which may intm-fere with contactless corminnicadon.
[01251 In yet another im.plementation of a contactless smart card, we employ a central issue (CI) type issuing m_odel when producing inventive contactless smart cards.. A
central issue model allows us to tightly control the materials and proc..%-sing of contactless smart cards.
[01261 These and further features, implementations r-md advantages of our contactless smart cards (or "contactless smart ED documents") will become even more evident with reference to the following disclosure and corresponding figures.
[0127] One implementation of a multi-layer contactless card. 60 (or smart ID
document) is disclosed with reference to FIG. 6. A ca-.-trier la-y7.--,r 61 is provided_ The carrier layer 61 carries or includes a contactless Srnqrt card mcdrae, suth as an antenna 100 (or tr,rsceiver, etc.), and electronic circuity 102 (see FIG. 1.0). The circuity 102 may include -processing and. memory circuity (c.a., 21<i-2561( bytes, etc.).
In some cases a chip operating systc.,-m is ciplGyCd with the inte2.4ieted. circuitr.y 102. The WO 03/056499 PCTitS02/41320 antenna commtinicates with the circuitry 102 through an interface or contact 104.
(Note that there rnsy be more or less contacts as shown in FIG. 10.). Of course, the antenna 100 can. include a plurality of receiving elements (e.g., loops or coils, copper wirhag, etc.).
[01.281 The carrier 61. is sandwiched between contact layers 62a and 62b.
Contact layers 62a and 62b raay include, e.g., a polymer, gyntb_etic, composite, etc., and can include a layered µ.1.s-racture such as a polymer-srihesive layering._ The carrier layer 61 is preferably permeable, e.g., like a mesh or scrim. The carrier layer 61 material can be com_posed of marLy different materials including, polyraers, PET
(polyethylene tplithalate), PET fibers, polycarbonate, polyester, poly-composite, polystyrene, cellulose ester, polyolefin, polysulfone, poly-bends, composites, etc., etc.
One suitable I material that includes contactless smart card circuity and t-,nsceiver m.ePris is provided by Hitachi Se_Li_iconductor (America), Inc., with US headquarters in San Jose, CA. (For exarnple, Hitachi can provide a scrim inlay, in sheet sizes of about 15 %"x24", including 6-by-6 wired anteudas and corresponding integrated circuits, each antenna/circuit/carrier layer have a dimension of about 45mmx77Ø. When using scrim sheets, and/or when a.iigniTg indi-vidn n1 ante,nnakircuity, some cm should be given to ensure proper align..,-nent of the carrier layer 61 (e.g., ate-I-el-1g the antenna/circuitry) when considering cutang (e.g.; die cutting), preprint information and/or person.alizadon of a contactless srrt Tit idmtifica-O.on doc,Tnent. If using a mesh material, we have found excellent results when using a mesh weight-per-area ratio in. a range of about 5 gains/m.2 ¨ 20 (-,21cLum/m2. Our most preferred niesh includes a redo of about 10 grains/m2. In some implements-ions the antenns 100 and intz.,--grated circuitry 102 are positioned or ell-the:Med betvyeeri two sheets of carrier (e.g., scrim or mesh) material. Of course, there are many other acceptable cauler layers and/or contactless smart card modules that are suitably interchangeable with fhis aspect of the present invention such as those provided by Philips and Sony, s-nong many others.
[01.291 A perneable carrier 61 facilitates the migration of contact layers 62a Pnd.62b into and/or throu.gh the earner layer 61 during a lrnr-inadon heat andlor pressure) process. The rni:gration of the ooritao.t layers into andlor through the carcier 61 helps to =
'WO 03/056499 PCT/1iS02/41320 firmly secure the -smart card module, including the contact 104 between the aMenna 100 and inteuated electronic circuitry 102.
[01301 In. an altemafive implouentation we embed (e.g., tbroucii inrjecli'on molding, lArni-rmi-ion, etc.) a coutactless smart card module in. a Garner layer 61.
The-rier layer 61_ is 'genera]iy solid instead of permeable in this imple-mentation. In this i_raplementation the cm-i= layer 61 preferably includes a material thql- is receptive to 1Rminadon or bong, e.g., a polynucr or adhesive rnRferiaL Izi still a futher alternative implementatiot.1, a carrier layer 61 comprises a m_etal or conductive rteria3.
(e.g., capper--w-iring). The carrier layer 61 itself serves as the antenna 100, which is coriiiected to the electronic circuitry 102 via a contact 104.
[01311 Regardless of which implementation is employed, contact layer 62a and/or 62b can receive indicia (or printing) provided thereon. The printing may include information that is typically associated with an identification document, such as a photographic representation of the card bearer, variable information, e.g., name, address, sex, height, weight, biometric information, signature, and/or citizenship, etc., etc. The printing may optionally include so-called fixed information such as information pertaining to an issuing authority, security feature (e.g., optical variable devices, etc.), etc. In other implementations, the indicia includes a digital watermark.
Instead of printing information on the contact layer 62a or 62b surface, we sometimes print information on an underside of an laminate/adhesive (e.g., 64a and/or 64b). If printing on an inner laminate or adhesive layer, the printing may be reversed so it appears properly oriented when viewed from an outer surface of the laminate or adhesive layer. In some implementations, the ink and printing techniques disclosed in U.S. Patent No. 7,143,950 to Robert Jones et al., entitled "INK WITH COHESIVE
FAILURE AND IDENTIFCATION DOCUMENT INCLUDING SAME", will be used to print a contactless (or contact) smart identification document.
Printing techniques may include offset, gravure, screen, thermal transfer, ink or laser jet, etc.

WO 014)56499 PCEITS02141320 [01321 In some impleuientations of our contactless smart M dociiment, we pre-print informadon onto a layer surface. The pre-printed information may inchidP
variable or xed infomaation.
[01331 Generally tansparent laminate layers 64a and 64b are provided over the contact layers 62a and 62b, respectivel-y. The laiminate. layers 64a and. 64b are secured to the contact layers, e.g., througk a conventional laminadon process involving heat andior p.I.ssure. Laminates like those discussed. above in Section I can be used here also Laminate layels 64a and 64b provide some degree of infrusion protecdon for Mfoi=iadon printed on the smart card, as well as provirg additional sb_Laigth and a m.oisture __ [01341 While specific rli-mensions may be dictated accorrhrg to idmdfloadon document required s'and Frds, we note that our preferred dimensions for the contactless smart identification document shown in FIG. 7 include: Gather (3-15 mils);
contact layers (3-16 mils); and. lnf-ite (2-15 roils). A preferred range of document depths is betwem about 2740 vnils, with our most prefened document depth includes about mils.
[01351 Further implementations and example.s of =tactless =art identification documents are discussed -witk reference to FIGS. 7-12.
[0136] With reference to F]IG. 7, contact layers 62a and 62b include an adhesive (AD)Ipolyrmeriadhesive (AD) stractize. The adhesive can be coated or layered oa the polymer. The polymer layers (62a and 62b) may be fonned from any polyraer, for example polyester, polystyrer_te, cellulose ester, polyolefin, polysialfone, or polyimide.
Either an amorphous or biaxiaLly oriented polymer may be used. But we use polycarbonate as our most preft.-aied polymer. The polyrzuer 62a a.-nd 62b can be colored, e.g., white, to help accentuate indicia provided. thereon or on the 1Proirte e layers 64a or 64b. (In some implementations (not shown), we even provide a synthetic with adhesive layers (e.g., adhesively coated TESI29, composite, poly-bend andlor paper iTigtead. of a polymer -- as a contact layer 62a and 62b material.). The contact layers 62a and 62b can optionPlly include coloration e.g., white, if desired.
The adhesive layers AD (or coa'ing) help secure the contact layers 62a and 62b to the carrier layer 61 and to the lr,rninate layers 64a and 64b during a lamina-non process. In one implementation the adhesive com.prises a co-extruded polyurethane (PL-) (e.g., with a soil point between about 230-290 F.). In another impleraentation we use an aliphatic PU-based adhesive, CLA-93A, from. Thermedics, Inc. in Woburn, MA. Still another suitable adhesive is KRTY as provided by Transilwrap, headquartered in Franklin Park, Miriois 60131 USA. Other suitable aribesives may include polyester, polyester urethane, pol-yether -urethane, pol-yolefin, poly-composites, theauloplasU-c adhesives, - and/or a hot melt or ultraviolet or therrnsIly cured adhesive; of course, an adhesive may =
be coated, extruded or cast on to one surface of the polymer layer. The laminate layers 64a and 64b can also include, e.g., a polymer, polycarbonate, polyester, polyester urethane, poly-couvosite, polystyrene, polybutylene terephthalate (PBT), cellulose ester, polyolefin, polyadfone, poly;rnide, and/or polybutylene terephthalate (PBT), etc.
Here a.ggin, our m.ost preferred la--rinate layers 64a and 64b each comprise polycarbonate. Polycarbona-te sheets are widely available, e.g., from GE
Plastics, headquartered in Pittsfield, MA.
[0137] With reference to FIG. 8, contact layers 62a and 62b preferably include an Adhesive (A_D2)/Polymer/Adhesive (AD1) structure, while the Imninptes (64a and 641) preferably include a Polymer/Adhesive. (AD3) structure. ArThesive 2 is selected so as to provide a favorable bond. with Adhesive. 1 and Adhesive 3. Similarly, Adhesive 1 is selected to favorably bond. with Prrnesive 9 mid 3. (In som.e cases, AA-The-sive 2 and Adhesive 3 will comprise the sme adhesive.). Our most preferred implementation employs a polycarbonate as the polymer and polyurethane as the adhesives. Of course, other materials as discussed above can be used instead. If tb.e adhesive layers include polyurethane, and since the foundation of polyurethane chemistry is generPlly based on isocyanate, a variety of monomers and ilifferemt reaction.s can be exploited for synthesis of polymeric r-mterials with desired properties, such as flexibility, touoimess, durability, adhesion, and -ON-stability by other additives. Addilional poly.u-e-hP-ne corapomads need not be explored here,-in; rathez, one inventive concept is applying different polyurethane compounds to the various layers to achieve desired properdes.

[0138] With referen.ce to FIG. 9, our contact layers 62a and 62b and our larni-nate layers 64a and 64b each comprise a polymer (or synthetic)/adhesive stmcture.
Th.e adhesive sides (or coating) contact one another to help form a bond. Our most preferred implementation employs a polycarbonate as the polymer arid a polyarethgne as the adhesive. Of course, other materials as discussed in this patent docnment and those known in the art as suitable equivalents can be used iristeali [0139] With reference to FIG. 1.1, we provide yet another example of a contactless =art identificafion document. We start with scrim irday sheets (e.g., with a sheet size of about 15 34" x 24" that include about 6 x 6 antenna 100/chip 102 stiactures, with each antenna/chip sic-tore haviuy a dimension of about 45mm Y 77-mm, as cap be supplied from ki.TLTACM). Of course the scrim inlay sheets can be cut or otherwise sized as well. The antemialchip structure is preferably disposed between (or embedded) two scrim layers or sheets to form a scrim core 110.
[01401 T.he scrim core 110 is preferably sandwiched between contact layers 112 and 114. Each contact layer 112 and 114 preferably includes a polycarbonate layer (a) Frd polyurethane layers (b and c) (e.g., each layer comprises about 2 mils of polyurethane CLA93A from Thellnedics, Inc.), about 8 mils of white polycarbonate as supplied by GE Plastics) and about 2 mils of polyurethane (e.g., CLA.93A)).
T.he polym-ethane layers (b and 0) can be coated, extruded, sprayed, layered, etc.
onto the polycarbonate layer (a). Some care is given to the alignment of the scrim 110 (e.g., including =duple antermalchip stractu_res) and contact layers 112 and 114 to allow for . favorable printing and cutting down S'ZP.:1-ri In. some situations, we can even provide a r4sexation mPricer (e.g., printing) on an outer surface of the polycarbonate or polyurethane to help properly alim the contact layers 112 and 114. In other cases we provide infonnation (e.g., so-called fixed indicia) on an outer surfa.ce of layer 112b and 11.4c. The -kJ-a ormation can be offset printed, xerouaphically printec..,1 laser printed, gravure pririted, etc., etc.

[0141] Contact layers 112 and 114 are secured to the scrim core 110. For example, we attach the contact layers 112 and 114 through a lamination process (e.g., a heated surface, roller, or iron press). The HI structure shown in FIG. 11 results (i.e., without the spacing as illustrated). A preferred resulting structure is an 8.5" x 11"
sheet, including a laminated scrim core 110/contact layer 112 and 114 structure. Of course, other sheet sizes can be used as well. If using an 8.5" x 11" sheet there are usually about nine antenna/chip structures per sheet. We have two preferred branches in our process at this point. A first branch includes cutting (e.g., die cutting) the sheet into blanks after the HI structure is assembled. Each blank includes one antenna/chip structure having a cross-section as shown in FIG. 11. The blanks can be, e.g., supplied to an over-the-counter issuing station, and further processed by, for example, printing personal information on the blank or on an over-laminate and/or programming the on-card chip.
[01421 The second branch, perhaps better suited for use with a central-is-sue model, is dismissed with reference to i_G. 12. The Ill strice .sheet including multiple ant-InFachip st-zuctmes) is even further protected by providing over-laininRte chsets 116a and 116b (e.g., 7 rnil clear polycarbonate, e.g., 29292W. supplied from.
GE
Plastics). In some cases, the over-larninat_as 116a and 116b an adhesive (not shown) to even further help the lp-minFedon process. The lxminwte layms 116a and 116b are.preferably person Pli7ed prior to lamhation. The personali7ation may include printing variable information (e.g., photographs, text, g_taphics, signaiures, etc., etc.) throu.- laser priinv'ng (e.g., Xerox's DOC12 laser painter), ink jet printing, o Met printing, screen-print:ine, etc. (We note that the printhg of vailthle infomialion is preferably reversely printed in the FIG. 12 implemented:on, since the print is providd on_ an inner surface of thelPrminste layers 116a and/or 116b. Thus, theprinted information appears meetly PliEned when viewed from. the =c-view mo;te" shown in FIG. 12.).
[01431 The over.-1Frrin.Pts 116a and 116b can be seemed to the H.1 stract-are thronzli, isrninprion. One iRminption techniques is a platen press, which receives the Hl structure and over-1Prninates 116a and 1.16b. The plates press includes upper and lower plates (e.g., Teflon coated metal or glass plates), which press (e.2., about 2.5K PSI) the HI structure and over-lamates 116a and 116b with heat (e.g., up to about 275 F) to form the112 structure (i.e., without the spacing as illustrated). The 1 -iiriRdon time varies between about 3-15 minutes, with an opdmal lprnirPrion of about 10 mirutes.
Of course, other launinadon techniques (e4..=.r., rollers, press, pads, etc.) can be used to secure the over-laminates 116a 2-nd 116b to the Hi structure. The isnliripted structure 112 is cat (e.g., die cut) to yield muld-contactless smart identification documents. Each of these contactless smart identification docu-ient can be proup-imerl as needed (e.g., the on-bomd. chip 102 car be proa-anuned to include personalized information such as pass codes, biometric information, identi.fication informafion, in.fonnafian corresponding to the cardholder or to informadon printed on the identification document, etc.).
[01441 While specific structures have been discussed with respect to FIG-S. 6-12, we note that mpry other implementations will fall within the scope of the present invention. For e-_-umple, addidonal lavers (e.2., la-ninate layers or print layers) can be =
added to the illustrated structures. Also, in. a few cases, we use a structure inch-Kling a contact layerIca.Trierlcontact layer structure, or a Pirinviteicontact layer/carder/contact fl layer structure. In another implementation, we provide a cavity in ma identification document and then secure a contactless smart card mod.ule in the cavity.
[01451 And while we have described ce-rtRin materials and dimensions for our con." tactless smut identification documents the present invendon should not be limited to such.. Indeed, the present invention includes many more contactless smart identification doeuments of different fiimensions and materials.
In-ventive Combinations [01461 In Rddidon to the inventive aspects detailed above and in. the claims, some of the inventive combinations with respect to (e.g., c.ont.actless) smart ]i.
docmnents include the following:

[0147] A. A method of manufacturing a contactless smsrt card comprising the steps of:
providing a first contact layer and a second contact layer, the first contact layer comprising.- a float surface and a back surface, and the second contact layer com.prisine-a front Ntizrace and. a back si-as'mc' e;
prodding an arillesive adjacently vv-ith at least the back surface of the first contact layer, providin.g an. adhesive adjacently vvith at least the back surface of the second contact layer;
providing a carrier having a top surface and a bottom surface;
c=-ombinin a the first contact layer, second contact layer and cattier to form a multi-layered au. octane, vitherein the carrier comprises an antenna and electronic circuity therein.
[01481 Al. T.he method of combination A, wherein the carrier comprises scrim and the electronic circuity provides at least some smart card fun.ctionslity.
[01491 A2. The method of combination Al, further comprising the steps of:
coating at least the front surface of the first layer; and coating at least the front surface of the second layer.
[01501 A3. The method of combination A2, wh.erein the coating colapiises polyttethane.,, and the first mid second layers each comprises polycarbonpfe.
[0151] A4. The method ofcorobimtion.A3, further comprising the step of is-minoring a top Imminate and a bottoni 1Prninste respectively so as to be in contact with the front surface of the first contact layer and the front surface of tht.-, second contact layer.
[01521 A5. The method of combination Al, Parther comprising the step of printing at least the first contact layer prior to said. combining step.

[0153] A6. The method of combination Al, further comwising provirii-n g a laminate over at least the -9-rgt contact layer, whuein the laminate comprises personalized information thereon, the information being document-holder specific.
[0154] B. A methiod of producina- __ ca...Tds or identification doements cOmprising the steps of:
pro-Triding a scrim core coraprising electrical circuity and an antenna: and providing the scrim core between a first layer and a second layer so that the first layer and second layer mi,4iate into or Through the scrim layer.
[015.5] Bl. The method of corrthifdon B, wherein the first layer and second layer each comprise polyca.rbonate.
101561 B2. The method of combination B1, wherein the first layer contacts a core top side and the second layer contacts a core bottom side, wherein the top side layer is coated with a first polyurethane material and the bottom side second material is coated with a second polyurethane material.
- [01571 B3. The method of any one of combinations B, B1 and B2, wherein the electrical circuitry operates to provide at least some smart card functionality.
(01581 B4. The method of combination B3, wherein the at least some smart card functionality comprises at least one of data carrier, data manipulation, access control, identification verification, biometric carrier and data processing.
(01591 C. A smart identification document manufactured by the method in any one of combinations A-A6 and B-B4.
[0160] D. A m.ethod of malf-i-na a contactless smart ide:ntificadon.
d.ocurnent provirling a carrier Layer incluclirlg at least a transceiver and electoric circuity, wherein the carrier comprises at least one perraeable area;
arranaing the carrier layer between a first contact layer and a second contact layer, and then securing the first contact layer and second contact layer to the carrier layer through at least one of heat and pressure so that at least a portion of one of the first contact layer and the second contAct layer migates into the carrier layer at the one peimea.ble area; and proving a first 1PrnirAte layer over at least the first contact layer.
[0161] Dl. The method of combination D, wherein indicia is provided on at least one of the first contact layer and the first 11-41-rti-t Pte layer prior to said pro-yid-41g- a first 1P-mi-nPte layer step. =
' [01621 D2. The method of combination D1 further comprising provieing a second 1R-minpte layer over the second contact layer.
[0163] D3. Tb.e method of com.billation DI. wherein the first contact layer and the first krrnittate layer each comprise a polymer.
[0164] D4. The m-ethod of combingtion D3, wherein the first contact layer couvrises an adhesivelpolymehesive stracture.
[01.651 D5. The method of combinadon D4 wherein the second contact layer comprises an adhesive/polymer/adhesive stacture.
[01661 D6. The method of combin.adon D3, wherein the first larni-riPte comprises a polymer/adhesive stactte..
[01671 D7. The method accorng to any orie of combirations D3-D6, wherein the polym_er com.prises polycarbonate.

[0168} D8. The method accorriing to combinPtion D7 viherein the adhesive comprises polyurethane.
[0169} E. A contactless smart idestificafion doormat-1i couiplising:
a first contact layer;
a second contact layer;
a carrier layer sandwiched in between the first and secõ-ond contact layers, the carrier layer including at least a trpnsceiver and electronic circuity;
-wherein at least a portion of the first contact laye,=-r Pìd the second contact layer have -niarated into the carrier layer; the mia=ation helping to sectre at least a portion of the transceiver or electronic circuitry to the first and second contact layers; and a first larninate layer covering the first contact layer maid a second lamiri9te layer covering the second contact layer.
[01701 El. The contactless smart icle,ncation doctrnerrt of combinadon E -Therein the carder comprises at least one of a scrim and mesh [01711 F. A method of manufacturing a contactless smart card comprising the steps of: =
proviering a first layer and a second layer, the first layer comprising a front surface and a back surface, and the second layer comprising a front sin--ar and a back stnface;
coating at least the back surface of the first layer -Aria an -rihesive;
coating at least the back surface of the second layer -Arith ariPM-Iasi r e ;
providing a core having a top surface and a bottom surface;
combining the first layer, second layer and core to form a core structure, the core stnacture cor.aprising the coated back surface of the first layer in contact ve-ith the top surface of the core and the coated back surface of the second layer in contact Vvith the bottom surf-ace of the, core, vl,rhiriein the core comprises an anten.na and ele-ctonic oircuity contained therein.

[0172] G. A method of producing smart idendficadon documents comprising the steps of:
providing a scrim core comprising electrical circuitry and an materna; and providing the scriM core between a first layer and a second layer.
Section 3: Manufacture of PET-Based identification Document =
[0173] The following section focuses primarily on id_entification documents.
In =
particular, we present an incredibly earth-friendly and easily recycle-able identification doertment at a relatively low cost-per card. In one implementation, we provide an identification document structure including PET (polyethylene terephthalate) materials.
PET material also has good strength and flexibility (with a low cracking tendency) and biab. Frti-abrpsion. properties ¨ while also providing advantageous cost efficiencies.
[0174] We envision thAt in some implementations of the present invention, otn-invendve a PET-base identification documents will be used in an over-the-cormter (OTC) issuing modeL As discussed in the background section above, over-the-cotmter ("OTC") identification documents are generally issued immediately to a bearer-who is present at a document-issuing station. An OTC assembling process provides an M

docittrent "on-the-spot". (An illustrative example of sn OTC assembling process is a Deparµment of Motor Vehicles C'DM-V") setting where a driver's license is issued to a person, on the spot, after a successful exwm ). la some instances, the very nature of the OTC assembling process results in small, sometimes compact, printing and cmi assembleis for printing the ID document. Of course, our inventive PET
identifies-ion documents can be used in a central issue (CI) model as well.
[01751 One ex P .ple of an OTC identification doenirent (as disclosed in our U.S.
Patent No. 6,066,594) is shown in FIG. 13. FIG. 13 shows a schematic cross-section through an over-the-counter iden_dnication doe=ent (card). The document comprises a core layer 112 formed of aza opaque white reflective polyolefn. (c.v.., a TESLIN sheet) and printed on both surfaces with fixed indicia 114.

WO 03/056499 PeritS02/41320 [01761 The printed core layer 112 is sandwiched between two polymer layers 116 formed from an Pmorphous or biaxially oriented polyester or other optically clear plastic such as polycabonate. Each of these polymer layers 11.6 is fixedly sec-ared to the core layer 112 by a layer 118 of adhesive. On the opposed side of each polymer layer 116 _from the core 112 is provided an inaage-receiving layer 120 suited to th.e acceptance of printt ed image or portrait or other variable indicia (indicat&cl sciaciiiatically at 122) by dye diffusion thermal twisfer methods. The material used to form the image-receiving layers 120 is chosen so as to be immiscible with the polymer system of the donor gheet used, in accordance with U.S. Patent No. 5,334,573.
[01771 With reference to kriG. 14, we present an inventive over-the-counter idendfication document includire PET materipls! in cont-Last to the PIG. 13 d_ocument, the bla 14 :7--tp1ei_rentauon is a coreless stacture. The docm-rtent primnily includes two PET layers (or )51-rns). Transilwrap, of Franklin Park, 11.õ provides a suitable polyethylene terephthalate (PET) film under the trade npme "TX?." In some implemeritions we provide an Frnorphou_s PET Elm or layer. Of course, there are many other PET films that can be .suitably interchanged with this aspect of present invention_ The two PET layers are com.binecl, e.g., throu..q.h a conventional Iraninadon process. As shown. in FIG. 12 we can use adhesive layers (e.g., theiiaoplasdc aclhesives ¨ preferably PET-based adhesives) to help secure the PET layers.
The adhesive layers can be coated or layered with the PET layers. A resulting structure PET
structure is cut into required identification document sized cards, if needed_ (We note that the doanmenf s height H can be adjusted according to required identification.
document specifications . For example, the PET layers are preferably between about 5-15 mils and the adhesive layers are preferably between about 2-10 rnilg. one implementation com.prises 1_0 mil PET layers (e.g., Transilw=rap's T)2 white PET
Film) arid 5 mil adhesive layers (e.g., Transilwrap's 10._TY (polyole-in)).
[01781 The outer surface of a PET layer preferably receives infem.afion or indicia provided thereon. The PET layer can include coloration; e.g., white to even better = accentuate the indicia. The in Formation can include, ee.g-., variable infort_naon such as a cardholder's name, address, photograph, signature, biometric information, etc. and/or fixed information (e.g., infoauation which is common to a number of cards, such as the issning authority, security features, etc.). The printing may also include a so-called digital watermark. The watermark may be embedded in a background tint or pattern, a graphic or photograph, etc. A watermark can also be embedded through text or font manipulation as well. While we preferably transfer information to the PET
layer through a dye diffusion thermal transfer -- or "D2T2" -- process, the PET
layer can also be offset printed, ink- or laser jet printed, laser etched, etc. We provide information on an outer surface of both PET layers in some implementations. We can also print information in stages. For example, we can pre-print fixed information on a PET layer or PET substrate prior to lamination (or after lamination) and before a second stage printing of variable information. The infouaalion can also include a reaistation or calibration marker to help alip, the identification document in subsequent printing steps.
[0179j The PET layer can be can be adapted to even better receive printed information.
For example, we can provide a receiving layer or "image-receiving layer"
on an outer surface of a PET film. The term "image" in this disclosure should be maderstood to include all forms of printed and transferred information incluaing images, graphics, text, machine readable code, and/or designs, etc., etc. The inaage-receiving layer (e.g., about a 2-20 micron layer) may be formed from any material capable of receiving an image, e.g., by dye diffusion theitual transfer. (in some cases we use Transilwrap's DITX receiving fluid as an image-receiving layer. In other cases, a polymer (e.g., PVC) is used to form an image-receiving layer is first dissolved in an organic solvent, such as methyl ethyl ketone, dichlororaethane or chloroform, and the resultant solution is coated onto the PET layer using conventional coating apparatus, and the solvent is then_ evaporated to form the image-receiving layer.
However, if desired, the receiving layer cau be applied to the PET layer by extrusion casting, or by slot, gravure or other known coating methods. Of course, other materials and receiving layers, e.g., such as those disclosed in U.S. Patent Nos. 5,334,573 and 6,066,594, may be suitable interchanged with this image-receiving aspect of the present invention.

[Q180 Itrniy he advantageous to coat the image-receiving material at a centralind production facility and then provide resultant "b1PrIlc" documents to a plurality of document issue stations (OTC stations) at which variable data is applied to the image-receiving layers of the idendfication documents.
[0181] Following the printing of information on an irrePge-receiving layer (if provided, otherwise after printing_ on the PET layer), a protective layer (not shown) is optionally affixed over at least a portion of the image-receiving layer. The protective layer serves to protect the relatively fragile image-receiving layer from damage, and also prevents bleeding of information (e.g., thei rial transfer dye) from the irn age-receiving layer. Materials suitable for forming such. protective layers are lmown to those skilled in the art of dye diffu.sion the/heal transfer printing and any of the con.ventioral materials may be used provided thst they have sufficient tansparency and sufficient adhesion to the specific image-receiving layer with which they are in contact and/or block bleeriing of dye from this layer. However, in keeping with the theme of -this aspect of the present imevention, we, preferably apply a transparent PET-based protective I p-ninpte, if used.
[0182] The protective layer may optionally provide addidonal security and/or features for the identification document. For example, the protective layer raRy include, a low cohesivity polymeric layer, an optically vaiable ink, variable information, an image printed in a.m ifil: which is readable in the infra-red or ultraviolet but is invisible in nonnal white light, an image printed in a fluorescent or phosphorescent ink, cohesive faihre irk or any other available security feature which protects the document agaimt ta-npenng or counterfeiting, and which does not coillyrornise the ability of the proteotive layer to protect the iderifificadon document against wear and the elements.
[0183] Vyrith reference to FIG. 15 we provide yet another alternative implementation of a PET-based identificadon document. In particular, we provide a PET
substrate, protected by PET protective la--nifiFtes. Of course we can use adhesives to help secure the PET laminates to the, PET substfete. The PET substrate is prefmably colored, e.g., a .w-hite opaque color. Prior to Ismingtion we provide, information (e.g.;
variable and/or fixed information) on an outer surface or surfaces of the PET substrate. The PET
substare (or PET laminate) cari be coated., prior to laminafion, with an i-nage-receiving inaterial as discussed above. The image-receiving material cm be provided betveren the PET laminate and PET substrate (e.g., on either or both of these layers).
The image-receiving material can be alternatively (or in addition to) provided on an outer auface of the PET laminate layer. If information is provided Or-I an outer-surface of a PET lpTninate, a thin filna protective coat or layer can be optionally provided over the information for enhanced. protection. A completed structure can. be sized according to need (e.g., height H). Our structure, however, preferably includes dimensions in the following ranges: PET substrate (5-25 mils); PET laminates (2-15 mils) and acihesive layers, if used (2-8 mils).
[0184] From the foregoing., it will be seen that our PET-basc.-d.
identification documents provides an over-the-comater identVication document that affords si,pi.ficmt improvements in durability (e.g., flexibility and crack-resistance) and earth-friendly characteristics (e.g., recycle and low-hazardous missions during production) as compared with the other OTC identification docirnents. These types of PET-based ID
docp-nents cari also be provided at a significantly lower cost than. other OTC
(and CI) docummits. Our PET-based id.entificadon documents can also provide a durable and secure identification document that is instantly produced over-the-counter. It should be appreciated that our PET-base identification document can also include so-called -blanks," or document structures without printing, or with printing but prior to persona1i7ing the doctrnent [01851 Wile we prefer that our PET identi-5cation doonments include all PET
materials, it should be apprecia_ted that our invendve PET-based 17) documerits need not be limited as necessarily incluclin..q. all PET. For example,, a polymer (but non-PET) over-larninate may be added., a non-PET aerhesive may be used, a non-PET imaze-c-q receiving layer is employed, etc. And of course the dyes. or ini and other security features. wiLl not generally be PET-based. Such deviations certainly fall within the scope of this aspect ofthe present invention..

PCDITS02.141320 Inventive Combinations [01861 In addition to the inventive aspects detailed above and in the clain-is, some of the inventive combinations Nvith respect to PET-based ID documents include the following:
[01871 A. A ooreless identificadon document comprisin_g:
a first PET (polyethylene terephthalate) film including a top surface and. a bottorn surface;
a second PET film including a top surface and a bottom surface;
an imPge-receiving layer provided on the first PET El= top =face; and an adhesive layer in contact with the first PET -91m bottom surface and the second. PET film top surface, the pdbesive serving to secure the first PET Bin and the second PET filmy to one another.
[01881 A1. The document of combination A, wherein the receiving layer comprises a layer capable of being imaged by dye diffusion thymycial n-Pnsfer.
[01891 .A2. The document of combinafion A wherein the irriage-raceiving layer comprises a layer capable of being imaged by gravure printing.
[01901 A3. The doc=ent of combinyafion A, wherein the image-receiving layer comprises a depth in a ranp.-ye of 2 to 15 microns_ [01911 A4. The document of combination A, wherein the first PET film and the second PET -51---1 each comprises a depth of about 10 mil [01921 A5. The docutuent of combinatioll A, wherein the adhesive layer comprises at least two adhesive layers.
[01931 M. The documr..--nt of corabiTv-itiGn A, wherein the adhesive comprises PET.

WO 03/056499 PCTXS021413.20 [0194] A7. T_he document of combinPon A, -wherein indicia is provided on the im.age-receiving layer.
[0195] AS. The document of combinafion A7, wherein a 1Pillirte, layer is provided over the indicia on the -1-rn,qge-receiving layer.
[01961 A9. The document of combination A7, wherein the indicia is provided through dye diu- sion theDnal u.aus.fer (D2T2).
[01971 A10. The document of combination. A7, wherein the indicia is provided through gravure printing.
[0198] A11. The document of combination A, farther comprising a second image-receiving layer provided on the second PET film top surface.
[01991 Al2. The document of combingti on Al 1, wherein indicia is provided on the second image-receiving layer.
[02001 A13. The document of combination Al2, wherein a 1Rmi-i ate layer is provided over the indicia ozì the second image-receiving layer.
[0201] A14. The document of any one of corabinatiorL3 A7 and A13, wherein the indicia comprises at least one of a digital watermark and information that is specific to one who will bear the document.
[0202] A15. The document of combination. A, wherein each of tb_e Erst md second PET layers comprises N-klita coloration.
[02031 A16. The document of combinauon A15, wherein each of the Erst and second PET layers comprises substantially amorphous PET.
[0204] B. An identification document comprising:
=

WO 03/(66499 PCITS02/41320 a PET (polyethylene terephthslate) core layer comprising a first surface and a second surface, a first layer of a substantially trmspa:rent PET fixed to the first surface of the PET
core layer, a second layer of a substantiallytr-ansparerit PET fixed to the second surface of the PET core layer; and at least one imsge-receiving layer capable of being receiving information the iniage-receiving layer being fixed to at least one of the first trans. parent PET layer and the first surfqce of the PET core layer.
[02051 31. The docpment of combination B, wherein the receiving layer comprises a layer capable of being imaged by dye diffusion thermal trPnsfer.
[0206} B2. T.he docrment of combination B wherein the image-receiving layer comprises a layer capable of being imaged by gravure printing.
[02071 C. ..A.n identification docn-ment com.prising:
a first PET (polyethylene terephthalate) Firri including a ton surface, and a bottom surface;
a second PET Elm including a top surface and a bottom surface; and an adhesive layer in contact with the first PET film bottom surface and the second PET film top suiface, the adhesive serving to secure, the first PET
film and the second PET rfim to one another.
[nos] D. A method of mplcin g an identification document compdsing the steps of:
providing a first PET (polyethylene, terephtbPlate) film including a top surface snd a bottoiii surface;
provirli-ng A second PET Ã1---; including a top surface and a bottoin surface;

providing an imqge-receiving layer adjacently arranged on the fral. PET an top sm-face; and providing an atrhesive layer so as to be in contact with the first PET flan bottom surface and the second PET film ton surface, the ad.hesive serving to secure, the first PET film to the second PET film.
[02991 D. A method of rn]ri-ne an identification document comprising the steps of:
providing a PET (polyethylene terephtlylPte) core layer comprising a -Frst surface and a second surface, providing a iln-st layer of a substantially ft-Pnsparent PET so as to be adjacently arranged with the first surface of the PET core layer;
providing a second layer of a substantially n-F4-ogparent PET so as to be adjacently arranged with the, second surface of the PET core layer, and provirliqg at least one image-receiving layer capable of being receiving infoutiation, the image-receiving layer being adjacently arranged with at least one of the first transparent PET layer and the first nu-face of the PET core layer.
Conclusion [92101 Having described and illustrated the principles of the technology with reference to specific impleidentatons, it will be re,cop--ii7ed that the teeinoloP_y can be implemented in many other, different, forms.
[092111 For example, while we have described a contact-type smart card module as inclnaine, e.g., a Hitachi AE 45C module, the present invention is not so limited.
indeed many other smart card modules are contemplated, e.g., Atnel's 1608, ModuleEight, and products from Philips, EVM, etc., etc. Of Gonne, other modules cm be used to facilitate similar'adclitional smart card Emotionality. A cavity can be formed to accommodate the various shapes and dina,e7.-1,sions of alternative smart card modules.
[02121 In at least one emborl'iment (not shown), IRminate layers are formed into a pouch into which the core layer slips. With a pouch; methods such as heat, pressure, arThedves. aid the like, are usable to bond the core layer to the pouch l.ra.tes. Those qlcilled in the art ri1i appreciate thatm-arly blown strictures and configa..--adons for lsrlinPa_ng are usable with the ..vention..
[02131 While we use tethis herein lilce "front" and "back," these te--Luasf7 arepio-vided p-riTnr4Tily for the reader's convethence. For exaxrsple, a sm..a-t card module can be provided on a "ilonf' side, instead of a "back" side as discussed in section 1.
[0214] The technology disclosed herein can be used in combination with other technologies. Examples include the techndogy detailed in the following patents or patent applications: U.S. Patent No. 6,923,378; U.S. Patent No. 6,827,277 and U. S.
Provisional Application No. 60/429,115 (filed 11/25/02 and publicly available). Also, instead of ID documents, the inventive techniques can be employed with product tags, product packaging, business cards, smart cards, bags, charts, maps, labels, etc., etc.
The term ID document is broadly defined herein to include these tags, labels, packaging, cards, etc.
[02151 'While nv-my features arta aspects of the. present M.tiozi have beezi disclosed it will be aRtireciati that not all aspects Frtd. fe,ature.s need be incorporated into each of the, following [0216] The particular com.bi_nations cfeierziezits and features in the above-de:died tanbodimmts are exempla ________________________________________ y only; the int,-_,=h-m,,g and substitt.thon of these teachings wit1a other teacp in thig and the above-idendfied paterat document: are also expressly conte.i, nplated_ [02171 The tecolog-y thsclosed herein cazi be used izi co iîtiziAith of=
tech:_nolocries. For -.;.=ple, ingtead of trPrlition1P1snaart cards, the in.veridve techniques can be err-ployed with idvitificadon documents, d.tive,r.s' licenses, pa.ssports, product tags, prorinct packaing, business cards,. bags, Cf, TrirTS, ibeIs, ets.
T:he terms "Smgrt card" and "snrt 1D docrinient" are broadly defined herein to include, such licc=-nses, passports, tags, lah.&isõ pack-AP-41z cards, etc.

PCT/[S02/41320 [02181 It should be appreciated that while specific dimendons and components have beeri presented herein (including the drawr'o..,p), the present inventiozi is not ited to -such dimenTions and specific, components. Indeed, r-IR-ly of the d.ot.;..u_tent dirnm-mion.s, Trmterials, pr.indng techniques and m.art card circuity can be interchanged without devigfrom.. the scope of the present invention.
[02191 The scope of the claims should not be limited by the preferred embodiments set forth herein, but should be given the broadest interpretation consistent with the description as a whole.
=

Claims (20)

WHAT IS CLAIMED IS:

1. An identification document comprising:
a core layer comprising a substantially compliant material, the core layer having a first side and a second side;
at least one antenna affixed to the first side of the core layer;
at least one integrated circuit chip electronically connected to the antenna;
and a bottom sheet comprising a substantially compliant material, the bottom sheet being attached to the first side of the core layer such that the antenna and the chip are encased between the core layer and the bottom sheet.

2. The identification document of claim 1 wherein the substantially compliant material comprises at least one of polyolefin, TESLIN, silica-filled polyolefin, reflective polyolefin, white polyolefin, and opaque polyolefin.

3. The identification document of claim 1, wherein the core layer is pre-shrunk prior to at least one of affixing the antenna, electronically connecting the antenna, and attaching the bottom sheet.

4. The identification document of claim 1, further comprising an image-receiving layer affixed to at least one of the second side of the core layer and the first side of the bottom sheet.

5. The identification document of claim 4, further comprising a first polymer layer constructed and arranged to add mechanical strength to the image-receiving layer.

6. The identification document of claim 5, wherein the first polymer layer comprises at least one of a polymer, polycarbonate, polyester, polystyrene, cellulose ester, polyolefin, polysulfone, polyamide, poly(ethylene terephthalate), and (ethylene terephthalate glycol).

7. The identification document of claim 4, wherein the image-receiving layer comprises at least one of a material capable of receiving an image by dye diffu-sion thermal transfer and a material capable of receiving an image by ink jet printing.

8. The identification document of claim 4, further comprising at least one indicium printed on the image-receiving layer.

9. The identification document of claim 8, wherein the indicium is printed using at least one of dye diffusion thermal transfer and ink jet printing.

10. The identification document of claim 1 further comprising a first adhesive layer attaching the bottom sheet to the first side of the core, wherein at least one of the core, bottom sheet, and the first adhesive layer is constructed and arranged so that the identification document has a substantially uniform thickness.

11. The identification document of claim 10, wherein the first adhesive layer includes a recess sized to accommodate the integrated circuit chip.

12. An identification document, comprising:
a first layer comprising a substantially compliant material, the first layer having first and second sides and adapted to absorb at least a portion of a stress applied to the identification document;
an antenna disposed adjacent to the first side of the first layer;
an integrated circuit chip operably coupled to the antenna; and a second layer comprising a substantially compliant material, the second layer having first and second sides and adapted to absorb at least a portion of a stress applied to the identification document, the second side of the second layer being fixedly coupled to the first layer, the second layer being constructed and arranged to substantially encase the antenna and the integrated circuit chip between the first and second layers.

13. The identification document of claim 12, further comprising a substantially rigid layer coupled to at least one of the second side of the first layer and the first side of the second layer.

14. The identification document of claim 13, further comprising an image-receiving layer coupled to the substantially rigid layer, the image-receiving layer comprising at least one of a material capable of receiving an image by dye diffusion thermal transfer and a material capable of receiving an image by ink jet printing.

15. An identification document, comprising:
a first layer comprising a substantially compliant material, the first layer having first and second sides and adapted to absorb at least a portion of a stress applied to the identification document;
an antenna disposed adjacent to the first side of the first layer;
an integrated circuit chip operably coupled to the antenna;
a second layer comprising a substantially compliant material, the second layer having first and second sides and adapted to absorb at least a portion of a stress applied to the identification document, the second side of the second layer, the second layer being constructed and arranged to substantially encase the antenna and the integrated circuit chip between the first and second layers; and a substantially rigid layer coupled to at least one of the second side of the first layer and the first side of the second layer.

16. The identification document of claim 15, further comprising an image-receiving layer coupled to the substantially rigid layer, the image-receiving layer comprising at least one of a material capable of receiving an image by dye diffusion thermal transfer and a mate rial capable of receiving an image by ink jet printing.

17. A method of making an identification document, comprising:
providing a first layer having first and second sides, the disposing an antenna adjacent to the first side of the first layer;
operably coupling an integrated circuit chip to the antenna;
substantially encasing the antenna and the integrated circuit chip between the first side of the first layer and a second layer, the second layer comprising a substantially flexible material and being constructed and arranged to mate with the first layer, antenna, and integrated circuit chip to form an identifi-cation document having first and second sides and a substantially uniform thickness; and attaching a third substantially rigid layer to at least one of the first and second layers.

18. The method of claim 17 further comprising applying an image-receiving layer to the identification document, the image-receiving layer comprising at least one of a material capable of receiving an image by dye diffusion thermal transfer and a material capable of receiving an image by ink jet printing.

19. The method of claim 17 further comprising forming at least one of a variable and a fixed indicium on at least one of the first and second sides of the identification document.

20. The method of claim 17 further comprising forming at least one of a variable and a fixed indicium on the image-receiving layer.