Patent ID: 6764882
Filing Date: 2004-07-20
Classification: B29C,G06K,H01L,H05K,Y10T

Abstract:
A method for fabricating a card in a first molding assembly having a first plate and a second plate forming a first mold cavity and a second molding assembly having a first plate and a second plate forming a second mold cavity, the card having a substrate having a circuit side and a back side, the substrate generally separated from a surrounding frame by a peripheral opening spanned by at least one connecting segment between the substrate and the frame, the substrate having at least one electrical circuit and at least one connector for communicating between the at least one electrical circuit and an external circuit, comprising:placing the substrate and the frame between the first plate and the second plate of the first molding assembly; engaging at least portions of the first plate and at least portions of the second plate of the first molding assembly with at least portions of the substrate and the frame; injecting a first material into the first mold cavity for molding a first plastic casting onto the circuit side of the substrate and encapsulating the at least one electrical circuit while leaving a peripheral portion of the circuit side free of the first material, the first plastic casting having an exposed surface; removing the frame, substrate and first plastic casting from the first molding assembly; clamping the frame, substrate and first plastic casting between the first plate and the second plate of the second molding assembly, at least a portion of the exposed surface of the first plastic casting compressed for sealingly engaging a portion of the back side of the substrate against the first plate of the second molding assembly; injecting a second material into the second mold cavity for molding a second plastic casting surrounding the first plastic casting and enclosing the peripheral portion of circuit side and an edge of the substrate, the second plastic casting having a peripheral outer edge; removing the frame and the substrate from the second molding assembly; and singulating the substrate from the frame.