Patent ID: 6036099
Filing Date: 2000-03-14
Classification: B32B,G06K,H01L,H05K,Y10T

Abstract:
A process for incorporating at least one electronic element in the manufacture of a plastic card, comprising the steps of:(a) providing first and second plastic core sheets;(b) positioning said at least one electronic element in the absence of a non-electronic carrier directly between said first and second plastic core sheets to form a core, said plastic core sheets defining a pair of inner and outer surfaces of said core;(c) positioning said core in a laminator apparatus, and subjecting said core to a heat and pressure cycle; said heat and pressure cycle comprising the steps of:(i) heating said core for a first period of time;(ii) applying a first pressure to said core for a second period of time such that said at least one electronic element is encapsulated by said core;(iii) cooling said core while applying a second pressure to said core;(d) coating at least one of said outer surfaces of said core with a layer of ink;(e) milling a region of said core to a controlled depth so as to form a cavity which exposes at least one contact pad of said electronic element.