IC card module, manufacturing method therefor, hybrid integrated circuit module, and manufacturing method thereof

A support member 1 is previously molded, a hybrid integrated circuit substrate 45 is placed thereon, and the support member 1 on which the hybrid integrated circuit substrate 45 is placed is placed in a metal mold, then again molded of a thermoplastic resin 2. The poured high-temperature thermoplastic resin 2 strikes on the support member 1 whose bottom surface is directly contacted on the metal mold and the surface of the striking portion is melted and integrated without being deformed . Therefore, full mold substantially covering an entire surface of the substrate is enabled. Epoxy potting is applied to a semiconductor chip and a coil derivation part.

BACKGROUND OF THE INVENTION
 1. Field of the Invention
 This invention relates to an IC card adopting a thermoplastic resin with a
 short solidification time, a hybrid integrated circuit device, and
 manufacturing methods therefor.
 2. Description of the Related Art
 Recently, good use of IC cards has been made in various places. For
 example, IC cards are in demand for ski lift tickets in a skiing ground,
 train tickets, a book of swimming pool tickets, etc., including credit
 cards; it is desired that the IC cards can be used even under hostile
 conditions.
 Generally, two types of sealing methods are adopted from the viewpoint of
 cost merit. In one sealing method, such means putting a lid on an
 insulating substrate on which circuit elements of semiconductor elements,
 etc., are mounted, generally called a case is adopted for sealing. This
 structure is a hollow structure or a resin is poured into the hollow
 structure.
 The other sealing method is transfer mold, famous as a semiconductor IC
 mold method. In the transfer mold, generally a thermosetting resin is
 adopted, a metal mold is raised to about 180 degrees, and the
 thermosetting resin is hardened (namely, thermally reacts and is
 polymerized and solidified) with the temperature maintained, then is taken
 out from the metal mold as a sealing body. To mount an IC chip on a lead
 frame, soldering is used, but generally is high-temperature soldering and
 a problem of solder melting does not arise.
 However, the sealing structure using a case requires a margin in a
 substrate so that the case does not come in contact with elements therein,
 enlarging the outside size.
 On the other hand, as seen from the description given above, the transfer
 mold involves hardening while heating and thus requires a long time for
 the process; productivity cannot be improved.
 Then, the applicant paid attention to a thermoplastic resin not requiring a
 long time. The thermoplastic resin is heated and melted without hardening
 reaction and if cooled, it is solidified (namely, becomes solid without
 reaction). Therefore, after the thermoplastic resin is poured, it is
 solidified if cooled; sealing can be provided in a short time. However, to
 seal with a thermoplastic resin, for example, with injection mold, the
 resin temperature at the pouring time is high (about 300 degrees) and
 solder is melted, causing a failure in electric connection of circuit
 elements mounted in an insulating substrate.
 Here, high-temperature solder may be used. However, considering degradation
 of insulating resin under a conductive pattern, low-melting-point solder
 is preferred. Then, the invention assumes that solder at about 180-250
 degrees is adopted in the description to follow.
 Generally, the rear face of an insulating substrate is exposed and there is
 a problem in insulation property between IC card insulating substrate and
 IC card module attachment chassis. There is a problem in resistance to
 humidity because of the entry of moisture on the interface between the
 exposed rear face of IC card insulating substrate and thermoplastic resin
 sealing the surroundings thereof.
 If a substrate inferior in thermal conductivity, such as a printed-circuit
 board, a flexible sheet, a glass substrate, or a ceramic substrate, is
 used, solder is melted.
 Further, in full mold using transfer mold, a gap is provided between the
 rear face of a substrate and a metal mold to draw a resin into the rear
 face of the insulating substrate. Thus, the gap is provided using a pin or
 by sandwiching the insulating substrate between the upper and lower metal
 mold parts. However, in injection mold using thermoplastic resin,
 injection pressure is high (50-200 Kg/cm2), thus the insulating substrate
 bends, a bonding wire is broken, etc.
 A pin trace remains in the pin-supported point and the appearance worsens.
 SUMMARY OF THE INVENTION
 The invention is to overcome the above-described disadvantages:
 first, by providing an IC card module comprising a support member being
 made of a thermoplastic resin and having an area on which at least a
 substrate is placed and a sealing member made of a thermoplastic resin
 into which an exposure part of the support member is melted and
 integrated; and
 second, by providing an IC card module comprising a support member being
 made of a thermoplastic resin and having a first groove and a second
 groove on which at least a substrate and a coil are placed and a sealing
 member made of a thermoplastic resin into which an exposure part of the
 support member is melted and integrated so as to substantially seal the
 substrate.
 The thermoplastic resin is a material which is melted when reaching one
 temperature and is solidified when cooled. Thus, the support member made
 of a thermoplastic resin previously placed in a metal mold is melted upon
 reception of the heat of a poured thermoplastic resin and is integrated.
 Therefore, the IC card insulating substrate is molded in one piece with
 the support member and the poured thermoplastic resin and the rear face of
 the substrate can be covered. The dielectric strength characteristic and
 moisture resistance can be improved.
 The invention is to overcome the above-described disadvantages third by
 providing an IC card module comprising a sealing member made up of a
 thermosetting resin provided covering solder and a thermoplastic resin
 into which an exposure part of the support member is melted and integrated
 so as to substantially seal the substrate.
 The melting temperature of the thermoplastic resin is very high (about 300
 degrees). However, a resin is applied to the solder portion, whereby the
 heat of the directly melted, poured resin is not transmitted and solder
 melting can be prevented.
 The invention is to overcome the above-described disadvantages fourthly by
 providing an IC card module comprising a support member being made of a
 thermoplastic resin and having a first groove and a second groove on which
 at least a substrate and a coil are placed, the substrate being mounted in
 the first groove and having a semiconductor IC electrically connected to a
 conductive pattern formed on a surface of the substrate, the coil being
 mounted in the second groove and electrically connected to the conductive
 pattern of the substrate, and a sealing member made up of a thermosetting
 resin provided bridging the groove and a thermoplastic resin into which an
 exposure part of the support member is melted and integrated so as to
 substantially seal the substrate.
 The injection pressure of the thermoplastic resin, for example, a PPS resin
 comes up to about 50-200 Kg/cm.sup.2 and causes the coil or the insulating
 substrate to shift, but the coil and the substrate are buried in the
 grooves and therefore the shift can be prevented in addition to preventing
 of melting of the solder described above.
 The invention is to overcome the above-described disadvantages fifthly by
 providing an IC card module comprising a support member being made of a
 thermoplastic resin and having an area on which at least a substrate is
 placed and means for abutting a metal mold on a plane, a line, or a point
 on a side and a sealing member made of a thermoplastic resin into which an
 exposure part of the support member is melted and integrated so as to
 substantially seal the substrate.
 The substrate is molded in one piece with the thermoplastic resin and the
 rear face of the substrate can be covered. The dielectric strength
 characteristic and moisture resistance can be improved. Moreover, if the
 abutment means is provided on the side of the support member, the poured
 resin can be extended to the side and rear face of the support member and
 the exposure area of the support member can be lessened; furthermore
 moisture resistance can be improved.
 The invention is to overcome the above-described disadvantages sixthly by
 providing an IC card module comprising a support member being made of a
 thermoplastic resin and having a first groove and a second groove on which
 at least a substrate and a coil are placed and means for abutting a metal
 mold on a plane, a line, or a point on a side, the substrate being mounted
 in the first groove and having a semiconductor IC electrically connected
 to a conductive pattern formed on a surface of the substrate, the coil
 being mounted in the second groove and electrically connected to the
 conductive pattern of the substrate, and a sealing member made of a
 thermoplastic resin into which an exposure part of the support member is
 melted and integrated so as to substantially seal the substrate.
 In addition to the above-described advantages, since the grooves are formed
 and the parts are mounted therein, the parts do not shift even under high
 injection pressure proper to the thermoplastic resin and a failure, etc.,
 can be prevented.
 The invention is to overcome the above-described disadvantages seventhly
 by, as the thickness relationship between the support member and the
 sealing member, thinning the sealing member so that the support member can
 be prevented from warping.
 When the melted thermoplastic resin is solidified, if it is contracted,
 owing to the strength of the support member, the IC card module can be
 prevented from warping.
 The invention is to overcome the above-described disadvantages eighthly by
 making the thickness of said sealing member thinner than that of said
 support member.
 The invention is to overcome the above-described disadvantages ninthly by
 providing an IC card module manufacturing method comprising the steps of
 providing a substrate having a surface undergoing insulating treatment, a
 conductive pattern formed on the surface, and a semiconductor element or a
 passive element electrically connected to the conductive pattern,
 providing a support member made of a thermoplastic resin, on which the
 substrate is mounted, having means for abutting a metal mold on a plane, a
 line, or a point on a side, holding the support member so that a rear face
 thereof abuts one metal mold part, pouring a melted thermoplastic resin
 into a space formed by the one metal mold part and an opposite metal mold
 part, and melting an exposure part of the support member by heat of the
 melted thermoplastic resin for molding in one piece.
 Since the support member is provided, such a complicated structure wherein
 a space is provided on the rear face of the parts for placement need not
 be adopted. Therefore, a failure caused by the pressure exerted on the
 insulating substrate, the coil, etc., by the high injection pressure of
 the resin can be prevented.
 The invention is to overcome the above-described disadvantages tenthly by
 providing a hybrid integrated circuit module manufacturing method
 comprising the steps of providing a substrate having a surface undergoing
 insulating treatment, a conductive pattern formed on the surface, and a
 semiconductor element or a passive element electrically connected to the
 conductive pattern, providing a support member made of a thermoplastic
 resin, on which the substrate is mounted, holding the support member so
 that a rear face thereof abuts one metal mold part, pouring a melted
 thermoplastic resin into a space formed by the one metal mold part and an
 opposite metal mold part, and molding in one piece so as to make thinner
 than the support member so that the support member can be prevented from
 warping.
 When the melted thermoplastic resin is solidified, if it is contracted,
 owing to the strength of the support member, the IC card module can be
 prevented from warping.
 The invention is to overcome the above-described disadvantages eleventhly
 and twelfthly by potting with a first resin reacting with the sealed
 material (semiconductor bare chip, fine metal wires or coil) and sealing
 with the thermoplastic resin.
 Since the first resin reacts with the sealed element, no slip occurs if the
 support member warps due to heat.
 The invention is to overcome the above-described disadvantages thirteenthly
 by applying satin work to the face of the sealing member opposed to the
 bottom of the support member, whereby if a surface sink occurs because of
 the groove formed in the support member, visual check can be made hard to
 make.
 The invention is to overcome the above-described disadvantages fourteenthly
 by forming a second groove and placing a coil therein. According to the
 structure, coil is disposed within the groove appropriately without
 straying off from the position.
 The invention is to overcome the above-described disadvantages fifteenthly
 by placing a potting resin for covering a semiconductor bear chip, placing
 a second resin for covering a first groove so as not to expose the surface
 of the potting resin, placing the support member in a metal mold, and
 sealing the support member with a thermoplastic resin; otherwise, the
 resin pouring pressure at the sealing time would be applied directly to
 the potting resin, warping the insulating substrate, leading to
 destruction of the chip.
 The invention is to overcome the above-described disadvantages sixteenthly
 by providing a step on a peripheral part of said metal mold part.

DESCRIPTION OF THE PREFERRED EMBODIMENTS
 Before embodiments of the invention are discussed, first, IC cards will be
 discussed briefly. Generally, a memory device such as flash memory and its
 peripheral circuitry are sealed in a thin plastic card in the form of an
 IC chip or a hybrid, or an IC with no memory is sealed. The IC cards
 containing memory are IC cards for rewriting data and storing the result
 therein or those for feeding data into a processor.
 The cards include a card with an electrode exposed for signal transfer to
 and from a processor, a card to which a connector is attached, and a card
 in which a coil is sealed with an electrode not exposed.
 Here, the type of card in which a coil is installed within a sealing member
 will be discussed. However, the invention can also be applied to the cards
 with an electrode exposed and the cards to which a connector is attached,
 needless to say.
 The points to be noted to mold of a thermoplastic resin as a plastic card
 will be discussed briefly.
 (1) Injection Molding Time
 An epoxy resin used with transfer mold needs to be left alone while it is
 thermally hardened in a metal mold, but the thermoplastic resin needs to
 be simply cooled and the molding time can be shortened.
 According to a document, while one cycle using epoxy is 30-180 seconds,
 that using thermoplastic resin of PPS is 10-20 seconds.
 (2) Resin Yield
 Although thermosetting resin cannot be recycled, thermoplastic resin can be
 recycled if heated; resin in a runner, etc., can be collected and
 recycled, whereby the yield can be improved.
 (3) Injection Molding Conditions
 Cylinder temperature: Is substantially the same as resin melting
 temperature and is about 290-320 degrees.
 Metal mold temperature: About 140-150 degrees to solidify.
 Injection pressure: 50-200 Kg/cm2 That is, if the problem in (3) is solved,
 costs can be drastically decreased because of (1) and (2).
 (4) PPS (Polyphenylene Sulfide): One of Thermoplastic Resins
 This resin, which is free of a hydrophilic group, has a water absorbing
 rate which is a half that of epoxy resin, but is inferior to epoxy resin
 in adhesion to leads and elements.
 In the conventional transfer mold, a gap must be provided between the rear
 face of a substrate and a metal mold to draw a resin into the rear face of
 the substrate. However, if a thermoplastic resin is thus molded, injection
 pressure causes the substrate to warp.
 Therefore, in the first embodiment, as shown in FIG. 1, a support member 1
 is previously molded, an IC card insulating substrate 2 is placed thereon,
 and the support member 1 on which the IC card insulating substrate 2 is
 placed, is placed in a metal mold, then again molded by a thermoplastic
 resin 3. The poured and melted thermoplastic resin 3 strikes on the
 support member 1 and the surface of the striking portion is melted.
 Therefore, full mold covering the rear face of the substrate 2 is enabled.
 An IC card module according to a first embodiment of the invention will be
 discussed with reference to FIG. 1 to FIG. 5.
 FIG. 1 shows a state in which the IC card insulating substrate 2 and a coil
 4 are mounted on the support member 1. FIG. 2 is a sectional view taken on
 line A--A in FIG. 1. FIG. 3 shows a state in which a sealing member 3 made
 of a thermoplastic resin is provided in FIG. 2.
 The support member 1 is previously molded of a thermoplastic resin and coil
 4 and insulating substrate 2, which refers to a substrate, at least a
 surface of which to be formed on, with a conductive pattern, is undergone
 insulating treatment, are at least mounted on the support member 1. An
 adhesive, etc., may be applied to the rear faces of the mounted parts for
 fixing the mounted parts. However, here, a first groove 5 and a second
 groove 6 are formed when the support member 1 is molded; the insulating
 substrate 2 is placed in the first groove 5, the coil 4 is placed in the
 second groove 6, and a thermosetting resin, such as an epoxy resin 7, is
 applied for protecting and fixing them. The coil 4 is connected to
 electrodes 8 of the insulating substrate 2 through solder and to form a
 coil derivation part 9, the first groove 5 and the second groove 6 are
 made connected through the derivation part 9.
 The coil varies in size (whole plane area containing a hollow part)
 depending on whether the coil is used for generating a magnetic flux
 signal and sending it, or the coil is used for receiving a magnetic flux
 signal and taking out it as an input signal. That is, since a signal is
 received at the coil, if the size of the link indicated by the phantom
 line indicating the coil grows large, the amount passing through the
 magnetic flux increases, thus a signal is easily input. Thus, the grooves
 and the coil are formed so that the coil of a size as large as possible
 can be placed in the support member 1 of a substantial rectangle. If
 corners are at the right angle like the corners of the support member 1,
 the insulating film of the coil is easily broken, thus the corners are
 chamfered. Since they are chamfered one round, an octagon is formed.
 Ceramic, metal, a printed-circuit board, a glass substrate, a flexible
 sheet, or the like is possible as the IC card insulating substrate.
 Particularly, if a metal substrate or an insulating substrate close to the
 metal substrate in thermal conductivity is adopted as the IC card
 insulating substrate 2, the substrate temperature rises in a metal mold
 because the pouring temperature of the thermoplastic resin 2 is high.
 However, since the substrate acts as a heat sink, temperature rise on the
 IC card insulating substrate 2 and melting of solder formed on the
 insulating substrate 2 can be prevented.
 Although not shown, a conductive pattern made of, for example, Cu is formed
 on the insulating substrate 2 and active elements of transistors, ICs,
 etc., and passive elements of chip resistors, chip capacitors, etc., are
 mounted through solder, providing predetermined circuitry. Here, without
 adopting solder for a part, electric connection may be made by silver
 paste, etc. If the semiconductor elements, etc., are mounted face up,
 connection may be made through fine metal wires by bonding.
 Subsequently, the support member on which the parts are mounted as shown in
 FIG. 2 is placed in a metal mold and melted thermoplastic resin 3 is
 poured for molding. The thermoplastic resin 3 for sealing is provided by
 injection molding, for example, and the resin pouring temperature is
 extremely high (about 300 degrees). To insert the IC card insulating
 substrate 2 having circuit elements mounted by solder into the metal mold
 and molding integrally, the solder is melted due to the poured
 high-temperature resin, causing cold solder of the elements. This problem
 noticeably arises particularly on a resin-based printed-circuit board
 because thermal conductivity is low. However, in the invention, because of
 covering with the thermosetting resin 7, heat transmission to the solder
 is suppressed and melting of the solder can be prevented. Moreover, if an
 epoxy resin is used, slipping of fine metal wires can also be prevented.
 This topic will be discussed later.
 When the support member 1 is molded, a filler for improving thermal
 conduction is entered in a thermoplastic resin, the support member 1
 itself absorbs heat as a heat sink, so that melting of solder can be
 furthermore prevented.
 Here, PPS (polyphenylene sulfide) is adopted as the thermoplastic resin.
 The metal mold temperature is fairly lower than that of transfer mold; it
 is about 130 degrees or lower. A liquid resin at 300 degrees is poured
 into the metal mold and is rapidly cooled and solidified in the metal mold
 at lower temperature. This cycle, which is about 10-20 seconds, is
 drastically shortened as compared with the transfer mold cycle (30-180
 seconds).
 When the IC card insulating substrate 2 with the circuit elements mounted
 is molded of the thermoplastic resin 3, it is advisable to previously pot
 the solder joint part, bonding wire and bare chip with the thermosetting
 resin 7, such as epoxy resin. Further, preferably the thermosetting resin
 has a thermal expansion coefficient equal to that of the IC card
 insulating substrate 2.
 That is, the above-described measure has the effect of particularly
 preventing fine metal wire (100 .mu.m or less) from falling down or being
 broken by poured resin pressure at the molding time of the thermoplastic
 resin 3. Generally, it is considered that if a thermoplastic resin is used
 as a sealing material, the potting resin is also a thermoplastic resin.
 However, the thermoplastic resin 3 is only in contact with the IC card
 insulating substrate 2 after molding and does not react with the substrate
 and is not bonded thereto. Thus, a stress occurs in the wire connection
 parts also containing fine and solid lines and solder connection parts
 because of thermal expansion coefficient mismatch between the
 thermoplastic resin 3 and the mounted parts and between the IC card
 insulating substrate 2 and the thermoplastic resin 3 as thermal shock
 occurs. Particularly, because of no reaction with the thermoplastic resin,
 wire slip occurs from warpage of the substrate and a broken line, etc.,
 occurs. However, if an epoxy resin is adopted as the potting resin 7, the
 epoxy resin itself strongly reacts with the sealing content and is bonded,
 thus slip is suppressed and the problems can be solved. Since the melted
 thermoplastic resin 3 does not come in direct contact with solder at the
 molding time, temperature rise in the solder portion can be suppressed.
 When a metal substrate is adopted, it acts as a heat sink as described
 above. Further, if the solder is coated with a resin, melting of the
 solder can be prevented furthermore reliably. With printed-circuit boards,
 ceramic substrates, etc., inferior in conductivity, solder is coated with
 a resin and the resin thickness and resin pouring temperature are
 adjusted, whereby melting of the solder can also be prevented and the
 printed-circuit boards, ceramic substrates, etc., can be used.
 The thermosetting resin 7 has also the following merit: If the resin 7 is
 placed in a groove, when molding of the thermoplastic resin 3 is executed,
 a dent is produced in the surface of the mold member 3 corresponding to
 the groove and a phenomenon called a surface sink occurs, resulting in an
 appearance failure. Also, the strength of the support member 1 drops. That
 is, when the melted thermoplastic resin 3 is poured and solidified, the
 whole warps because of contraction. However, the groove is covered with
 the thermoplastic resin, thus the surface sink can be suppressed and the
 strength improves; the problems can be solved. When a surface sink occurs
 and the appearance is unsightly, all the area of the side where the
 surface sink occurs is made into satin worked surface, whereby judgement
 in a visual inspection is made hard to make.
 As seen in FIG. 2, steps 19 are provided in the surroundings of the rear
 face of the support member 1 for improving adhesion to the poured
 thermoplastic resin 3.
 Further, the support member 1 abutting a side of a lower metal mold is
 provided with means for coming in plane, line, or point contact therewith.
 In FIG. 3, semispherical abutment means 10 is provided. The abutment means
 10 has the two merits: One merit is to provide a good resin pouring
 passage in forming a gap between a side of the support member 1 and a side
 of the metal mold and sealing also containing the steps 19 and the sides.
 As the other merit, if the abutment means is not provided, a gap cannot be
 formed and the side is not coated with a thermoplastic resin either. That
 is, if sealing is executed without providing the abutment means, the
 interface between the support member 1 and the sealing member 3 made of
 the thermoplastic resin becomes d and a problem is left in moisture
 resistance. However, if the support member 1 is abutted in point or line
 as in FIG. 3, the sides of the support member 1 are almost covered with
 the sealing member, so that the moisture passage can be extended and
 moisture resistance can be improved. In FIG. 4, numeral 11 exaggeratedly
 shows a trace of the abutment means after sealing with the sealing member
 3. A completely sphere would be exposed at a substantial point. If a gap
 is somewhat formed, the portion exposed at a point can be covered thinly.
 FIG. 5 shows three types of abutment means of the support member 1. Numeral
 10A is abutment means of a rectangular parallelopiped for coming in plane
 contact with a metal mold. Numeral 10B is abutment means provided by
 cutting the rectangular parallelopiped to a half and having triangular
 sides for coming in line contact with a metal mold. Numeral 10C is
 abutment means provided by cutting the corners of the abutment means 10B
 for somewhat coming in plane contact with a metal mold.
 In any way, if the abutment means does not exist, a resin cannot be formed
 in the sides or the steps 19. That is, if an attempt is made to form a gap
 without providing the abutment means, when the support member 1 is placed
 in a metal mold, clearance is produced and resin pouring pressure is high,
 thus good molding cannot be executed.
 A thickness problem also occurs between the support member 1 and the
 sealing member 3. Although the support member 1 is previously formed, the
 sealing member 3 abuts the support member 1 in a metal mold and is
 solidified. When the sealing member 3 is solidified, it contracts, thus
 the support member 1 needs to be thickened so as not to warp against the
 contraction of the sealing member 3. Conversely, the sealing member 3
 needs to be thinned.
 Subsequently, a second embodiment of the invention will be briefly
 discussed with reference to FIG. 6 and FIG. 7. FIG. 6 shows the shape of a
 support member 1. FIG. 7 shows the support member 1 on which a coil 4 and
 an IC 7 are mounted, sealed with a thermoplastic resin. In the first
 embodiment, the first and second grooves which are each a rectangular
 parallelopiped in cross section are formed; in the second embodiment, a
 projection wall 20 like a castle wall is provided for forming a groove.
 Because of such an uneven shape (having an indented surface), the contact
 plane with the sealing resin widens and the sealing strength and moisture
 resistance can be improved. However, because of the uneven shape, a
 surface sink occurs and to prevent it, a thermosetting resin needs to be
 applied to the whole face.
 In both the first and second embodiments, steps 19 are provided, whereby
 adhesion to a poured resin improves. However, since the support member 1
 is made of a thermoplastic resin, if it is attached to a metal mold and a
 resin is poured, deformation may occur because a gap exists in each step.
 Therefore, if a projection having the same level as the rear face of the
 support member 1 is attached to each step, the problem can be solved. The
 size, the shape, the number of pieces, and the like are determined
 considering the IC card module size, injection pressure, etc.
 For the support member 1, particularly requiring external heat radiation, a
 filler for improving thermal conductivity may be mixed into the support
 member 1 considering substrate temperature rise caused by poured resin 3.
 For example, alumina, SiO.sub.2, etc., is mixed. Resin is also brought
 into the rear face of an island fixedly secured to a transistor like
 transfer mold of a transistor chip. If a gap is made in the rear face and
 resin for the support member 1 is poured to mold the support member 1 and
 an IC card insulating substrate 2 in one piece in a metal mold, thermal
 conductivity is excellent and heat is absorbed in the metal mold at the
 molding time and is not brought into the whole rear face of the substrate.
 Therefore, it is important to previously provide the support member 1 and
 place mounted parts therein. A thermoplastic resin into which a filler is
 not mixed is used as the poured resin 3; otherwise, heat of the poured
 resin 3 is absorbed in a metal mold and the poured resin 3 is solidified
 at a midpoint of the IC card insulating substrate 2.
 Last, a metal mold will be briefly discussed with reference to FIG. 4. The
 upper part of FIG. 4 is a perspective view of a complete IC card module
 and the lower part is an illustration of the IC card module pushed out by
 a push-out pin of a plane push structure. Numeral 30 is a lower metal
 mold. Abutment means 10 attached to the support member 1 abuts a metal
 mold side 31. An upper metal mold (not shown) is closed for forming a seal
 space, and a melted thermoplastic resin is poured into the space. The
 poured resin is injected from between the abutment means 10 and 10 to step
 19 and is solidified due to the metal mold temperature. If a fine pin is
 used, a trace is left, thus a pin 32 of a plane push structure is used as
 the push-out pin. Since the abutment means 10 is shaped like a semisphere,
 some traces are left, but can be made inconspicuous by performing satin
 finish to the surface of the abutment means 10. A dent 33 is a portion for
 the user to put a used seal, etc.
 FIG. 8 shows placement of the area in which the insulating substrate 2 is
 placed in FIG. 1 in a corner of the support member as such a structure not
 exerting a bending force on the insulating substrate. For example, if a
 person enters a complete module in a hip pocket, the module will be apt to
 be bent mostly at the center thereof. Therefore, if the insulating
 substrate can be placed in a quarter the area inside the coil (square area
 indicated by X mark) so that it is smaller than the quarter area, even if
 the module is bent, the insulating substrate of the circuit substrate is
 not affected. Numeral 40 is a potting resin (for example covering a
 semiconductor chip, numeral 41 is a potting resin covering a coil
 derivation area, and numeral 42 is a guide for preventing the derived coil
 from being short-circuited. Numeral 43 is a stopper regulating a move of
 the coil.
 FIG. 9 is a sectional view taken on line A--A in FIG. 8, wherein the
 potting resin 40 covers a semiconductor chip 45 and further the groove is
 covered with an epoxy resin 44. If the epoxy resin 44 does not completely
 cover the potting resin 40, when thermoplastic resin is poured for
 sealing, pressure proper to injection is exerted on the portion indicated
 by the arrow and the semiconductor chip is broken. This phenomenon occurs
 because pressure is applied intensively to the potting part of the arrow
 portion. If the potting part is completely covered with the epoxy resin
 44, pressure does not concentrate on the potting part, thus the
 semiconductor chip is prevented from being broken.
 As described above, first, the thermoplastic resin is a material which is
 melted when reaching one temperature and is solidified when cooled, thus
 the support member molded of a thermoplastic resin previously placed in a
 metal mold is melted upon reception of the heat of a poured thermoplastic
 resin and is integrated. Therefore, the IC card insulating substrate is
 molded in one piece with the support member and the poured thermoplastic
 resin and the rear face of the substrate can be covered. The dielectric
 strength characteristic and moisture resistance can be improved.
 Second, although the injection pressure of the thermoplastic resin is
 large, the mounted parts do not shift and are not destroyed as the grooves
 are formed.
 Third, since the solder of the conductive pattern of the IC insulating
 substrate is covered with the resin, although the melting temperature of
 the thermoplastic resin is very high (about 300 degrees), the heat of the
 directly melted, poured resin is not transmitted and solder melting can be
 prevented.
 Fourthly, the injection pressure of the thermoplastic resin, for example, a
 PPS resin comes up to about 50-200 Kg/cm2 and causes the coil or the
 insulating substrate to shift, but the coil and the substrate are buried
 in the grooves and therefore the shift can be prevented and sealing is
 enabled in addition to preventing of melting of the solder described
 above.
 Fifthly, the thermoplastic resin is a material which is melted when
 reaching one temperature and is solidified when cooled, thus the support
 member molded of a thermoplastic resin previously placed in a metal mold
 is melted upon reception of the heat of a poured thermoplastic resin and
 is integrated.
 Therefore, the IC card insulating substrate is molded in one piece with the
 support member and the poured thermoplastic resin and the rear face of the
 substrate can be covered. The dielectric strength characteristic and
 moisture resistance can be improved.
 Sixthly, although the injection pressure of the thermoplastic resin is
 large, the mounted parts do not shift and are not destroyed as the grooves
 are formed.
 Seventhly, since the solder of the conductive pattern of the IC insulating
 substrate is covered with the resin, although the melting temperature of
 the thermoplastic resin is very high (about 300 degrees), the heat of the
 directly melted, poured resin is not transmitted and solder melting can be
 prevented.
 Eighthly, the injection pressure of the thermoplastic resin, for example, a
 PPS resin comes up to about 50-200 Kg/cm2 and causes the coil or the
 insulating substrate to shift, but the coil and the substrate are buried
 in the grooves and therefore the shift can be prevented and sealing is
 enabled in addition to preventing of melting of the solder described
 above.
 Ninthly, the thermoplastic resin is a material which is melted when
 reaching one temperature and is solidified when cooled, thus the support
 member molded of a thermoplastic resin previously placed in a metal mold
 is melted upon reception of the heat of a poured thermoplastic resin and
 is integrated. Therefore, the IC card insulating substrate is molded in
 one piece with the support member and the poured thermoplastic resin and
 the rear face of the substrate can be covered. The dielectric strength
 characteristic and moisture resistance can be improved.
 Tenthly, although the injection pressure of the thermoplastic resin is
 large, the mounted parts do not shift and are not destroyed as the grooves
 are formed.
 Eleventhly, since the solder of the conductive pattern of the IC insulating
 substrate is covered with the resin, although the melting temperature of
 the thermoplastic resin is very high (about 300 degrees), the heat of the
 directly melted, poured resin is not transmitted and solder melting can be
 prevented.
 Twelfthly, the injection pressure of the thermoplastic resin, for example,
 a PPS resin comes up to about 50-200 Kg/cm2 and causes the coil or the
 insulating substrate to shift, but the coil and the substrate are buried
 in the grooves and therefore the shift can be prevented and sealing is
 enabled in addition to preventing of melting of the solder described
 above.
 Thirteenth, by potting with a first resin (in this case, epoxy resin)
 reacting with the sealed material (semiconductor bare chip, fine metal
 wires or coil) and sealing with the thermoplastic resin, no slip occurs if
 the support member warps due to heat.
 Fourteenthly, by applying satin work to the face of the sealing member
 where a surface sink occurs, opposed to the bottom of the support member,
 visual check can be made hard to make.
 Fifteenthly, by placing a potting resin for covering a semiconductor bear
 chip, placing a second resin for covering a first groove so as not to
 expose the surface of the potting resin, placing the support member in a
 metal mold, and sealing the support member with a thermoplastic resin, the
 resin pouring pressure at the sealing time is not directly applied to the
 potting resin, so that destructing of the chip can be prevented.