Patent ID: 6514367
Filing Date: 2003-02-04
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, the second pressure being at least 10% greater than the first pressure; and (d) 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 at least one electronic element.