Patent ID: 6444501
Filing Date: 2002-09-03
Classification: B29C,G06K,H01L,H05K,Y10T

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