Method for producing a plastic material composite component, a plastic material composite component and a mold for injection molding same

A method for producing a plastic material composite component and a corresponding component are disclosed. The component is typically a smart card having a semiconductor chip embedded in plastic material. The component is provided with a contact area on an outer component surface. Electrical interconnection between the contact area and the chip is effected during injection molding the component.

FIELD OF THE INVENTION 
The invention relates to a method for producing a plastic material 
composite component having a semiconductor chip embedded in the plastic 
material. 
Further, the invention relates to a plastic material composite component 
comprising at least one label configuring a flat side of the component, 
and a chip embedded in a plastic material adjoining the label. A component 
of this kind may, for example, be a credit card or, still more 
specifically, a so-called smart card. 
The invention, moreover, is related to a mold for injection molding a 
plastic material composite component of the kind described before. 
BACKGROUND OF THE INVENTION 
The invention relates to a method for producing a plastic material 
composite component during which a cavity in a plastic material injection 
molding machine is repleted with molten plastic material by injecting same 
and the chip is embedded in the plastic material. An electrical contact is 
made between the chip and a surface of the composite component. 
Although the invention will hereinafter be described in relation to the 
production of so-called smart cards, it is to be understood that the 
invention is not limited to this field of application. 
The term smart card is used to describe a plastic card with one or two 
laminated sides which usually carry some instructions and/or advertising 
printed thereon and/or certain safety features, for example a hologram, a 
magnetic strip, a photograph of the card holder, or the like. A module is 
embedded in the smart card. The module consists of an integrated 
semiconductor electronic circuit (chip) and, usually, of a 
contact-and-carrier plate carrying the chip. In the case of some cards, 
the chip coacts with a plurality of surface segments to form electric 
contacts that are accessible from the outside. In the case of other cards, 
antennas are provided in the card for the non-contact exchange of 
information, for example of data. Smart cards of that kind are employed as 
telephone cards, authentication cards for mobile communication equipment, 
as credit cards for money transfers, as authorization cards for medical 
insurance systems or the like. 
The user of such cards introduces the smart card into, or moves past a card 
reader which thereby enters into communication with the electronic chip in 
the smart card via corresponding contacts or antenna means. 
In order to enable smart cards to be simultanously used as advertising 
means, the smart cards preferably are produced in such a way that one or 
two films, preferably so-called labels, are employed to form one or both 
flat sides of the finished smart card. In this connection, the term 
"label" is understood to describe a film with, preferably, one printed 
side. The label carries the advertising imprint, or the like. 
For producing the smart card, the label is introduced into the cavity of a 
plastic injection mold. For this purpose, the cavity has a flat, 
parallelepiped shape, and the labels are placed on the flat surfaces of 
the cavity. 
The invention, further, is related to the production of similar cards, as 
have become known under the denomination "data-cards" or "PCMCIA". These 
cards are laminated on one or both flat sides with a metal foil or film 
and have the shape of a conventional credit card, however, are somewhat 
thicker so that even more complex electronic componentes may be embedded 
therein. Such data cards are used for securing data and are also used as 
access authorization elements for highest security standards. PCMCIA cards 
are, inter alia, used in portable electronic data processing and 
communication equipment, for example in notebooks and may contain a modem, 
supplemental memory or a standardized interface, for example for coupling 
the communication equipment to certain telephone or other data 
communication networks. 
Such PCMCIA cards conventionally have a groove on a narrow front side, the 
groove, in turn, being internally equipped with female contact segments 
which, when the PCMCIA card is inserted into a corresponding PCMCIA slot, 
come into contact with corresponding male contact elements provided in the 
slot. 
For producing either credit cards, smart cards or PCMCIA cards, molten 
plastic material is injected into an appropriate cavity of a mold. The 
plastic material may be any appropriate material, for example polystyrol, 
propylene, ABS or polycarbonate, resulting in a perfect adhesion between 
the labels and the plastic material after the termination of the injection 
process. 
European patent document 0 399 868 discloses a process for manufacturing a 
smart card of the kind of interest. For doing so, the chip is first 
mounted on a metal band and is wired concurrently. The chip together with 
the metal band is then embedded in a plastic material so that a module is 
produced having a certain thickness. The module is configured such that 
its thickness corresponds to the height of the cavity within the mold. 
When the mold is closed a certain pressure is thus exerted on the module, 
fixing same at a certain predetermined position within the cavity. 
According to this prior art method a contact area is provided being 
subdivided into certain segments according to the requirements of a 
specific application. The chip is connected to the segmented contact area 
by soldering its connectors onto individual segments of the contact area 
via contact wires. Subsequently, the chip and the contact area are 
embedded in a resin within a mold for producing the module which is then 
subsequently inserted between the foils and into the cavity, as described 
before. In a subsequent step the cavity is then repleted with plastic 
material by injecting same. In some applications an array of contact areas 
is arranged on a flat metal band or on an electrically conductive foil or 
film having the shape of a band. The chips are then individually bonded, 
are then subsequently embedded to generate modules and are finally 
separated from each other by cutting. This contacting of chips on bands is 
also known in the art as "tape-bonding". 
Conventionally it had been considered as necessary to produce a module, 
i.e. the chip with its contact surface, as a separate element in order to 
be able to protect the chip against any adverse effects occurring during 
the manufacture of a smart card and in order to ensure a safe bonding with 
the contact area. 
However, it is certainly disadvantageous that the modules are manufactured 
separately because this involves additional and time consuming production 
steps. 
The prior art, further, has the disadvantage that the positioning of the 
module within the mold cavity may be guaranteed only with difficulties. 
The forces required for fixing the module within the cavity at a 
predetermined location may only be generated after the mold has been 
closed so that the modules might change their position during the closing 
of the mold. 
It is, therefore, an object underlying the invention to improve a method, a 
component and a mold of the kind mentioned at the outset, so that the 
afore-mentioned disadvantages are obviated. In particular, the various 
method steps that are required for the production of such components shall 
be reduced in number and shall be simplified in order to enable a reliable 
and economical production. 
These and other objects of the invention are achieved by a method for 
producing a plastic material composite component having a semiconductor 
chip embedded in the plastic material, the method comprising the steps of 
providing a plastic material injection mold having a cavity; 
providing the chip in the cavity; 
providing electrical connection elements in the cavity; 
injecting molten plastic material into the cavity, thereby embedding the 
chip in the plastic material and simultaneously arranging the chip and the 
connection elements such that an electric contact is fixed between the 
chip and a surface of the cavity when the chip is arranged in the cavity. 
The objects are, further, achieved by a plastic material composite 
component comprising at least one label configuring a flat side of the 
component, and a chip embedded in a plastic material adjoining the label, 
the chip being mounted on a carrier element and the carrier element being 
attached to the label, a contact surface being provided on the component, 
the chip having contact bumps electrically connected to the contact 
surface by soldering or riveting. 
Moreover, the above-mentioned objects are achieved by a mold for injection 
molding a plastic material composite component having a chip embedded 
therein by injecting a molten plastic material into a cavity of the mold 
after inserting the chip into the cavity, the mold comprising: 
a first mold portion; 
a second mold portion adjoining the first mold portion with the cavity 
therebetween when the mold is in a closed operational position; 
means for inserting the chip into the cavity when the mold is in an open 
operational position; 
means for mechanically making an electrical contact between the chip and a 
contact surface on the component when the chip is arranged in the cavity, 
the contact making means being provided in the first mold portion and 
extending through an opening in the cavity. 
The object underlying the invention is thus entirely achieved. 
The invention makes the separate production of modules superfluous in which 
the modules are produced by embedding the chips and a contact area in a 
resin. Nevertheless, a precise and reliable contact between the chip and 
the surface of the composite component is achieved during the injection of 
the molten plastic material into the mold cavity. 
Therefore, the production of such components is highly simplified because 
several production steps may be deleted and, further, it is only necessary 
to precisely insert the chip into the cavity and hold same on that 
position during the injection process. 
According to the invention, the contact is fixed during the injection 
process, i.e. it is finally arranged because the corresponding contact 
elements had been inserted loosely into the cavity before. 
In any case it is possible to insert the chip into the plastic material 
during the injection of the latter or to insert it into the cavity prior 
to injection. 
In the scope of the present invention the term "chip" is to be understood 
in a broad sense and may comprise individual electronic components or 
assemblies or arrays of such components. In the colloquial language the 
term "chip" is normally related to an electronic component where the 
semiconductor substrate, i.e. the wafer, is entirely encapsulated in a 
plastic material housing and its contacts are bonded to mechanical 
contacts or contact tongues by well-known techniques. Although the present 
invention envisages to use such commercially available elements, it is 
also considered to use the wafers by themselves, i.e. wafers that have not 
already been embedded in a plastic material housing. 
According to the invention it is preferred to use a semiconductor component 
having contact bumps on its surface and to embed same into the plastic 
material without surrounding the semiconductor component with another 
plastic material before. 
This results in a further reduction of manufacturing steps, i.e. the 
manufacture of a housing or a module and, hence, results in substantial 
savings of time and money. Further, even smaller dimensions become 
possible because no separate and space consuming housings for the chips or 
the modules are required. 
According to an embodiment of the invention the contacting itself is made 
during the injection time. 
This feature has the advantage that a further step, i.e. the separate 
manufacture of the contact becomes superfluous. Therefore, a further 
reduction in cycle step and a further reduction of costs is achieved. 
According to another embodiment of the invention the chip is arranged on a 
foil, film or a label which, later on, constitutes a flat side of the 
composite component. The chip and the label are synchronously inserted 
into the mold cavity. 
The positioning of the label together with the chip may be made 
conventionally by applying a vacuum, by applying electrostatic forces or 
the like. As the position of the foil may be easily ensured when inserted 
in the cavity, the position of the chip is also ensured because the chip 
is fixedly attached to the label. 
Therefore, in contrast to the prior art it is not necessary to use two 
separate positioning steps, one for the label and one for the module and 
no further steps must be taken to guarantee that the module will remain on 
its particular position. Thus, the position of the chip on the foil and, 
hence, within the cavity may even be guaranteed during the closing of the 
tool. 
According to an alternate embodiment of the invention, the chip is not 
attached to the label prior to the beginning of the injection cycle. 
Instead, the chip is mounted on a part of the mold, for example by 
applying an appropriate adhesive and gluing the the chip on the tool. 
In a preferred embodiment of the invention the chip has bumps on its 
surface and is electrically connected to the contact area. 
This feature has the advantage that the contact bumps may be geometrically 
located accordingly so that they may immediately be soldered or connected 
by pressure to a corresponding counter-surface, thus establishing an 
electrically conductive connection. The contact bumps may be inserted into 
corresponding openings in the label. In such a way an electrically 
conductive connection to the contact area may be established without the 
need of a complex bonding process as used in the prior art where fine 
wires are bonded to the contact bumps on the semiconductor substrate. 
It goes without saying that the term "contact bumps" shall include any 
contact points on the surface of the chip and may substantially vary in 
their specific design, depending from the particular chip or varying 
between various chip manufacturers. However, contact bumps are 
conventionally configured so as to withstand certain mechanical stress so 
that they may be soldered with a soldering agent melting at low 
temperatures or may be bonded accordingly. 
The contact area itself may be generated either before or during the 
injection process. The generation of the contact area after the injection 
process is particularly preferred because during the injection process the 
fixing of the contacting occurs, i.e. the electrically conductive 
connection between the contact bumps and the composite component outside 
surface. Therefore, after the injecting the contact area may be 
manufactured particularly simply and may be connected with the contact. 
Further, it is also possible to only mechanically prearrange the contact 
during the injection and to complete same after the injection. 
In a particularly preferred embodiment of the invention the contact bumps 
are configured as rivets being riveted with the label during the injection 
process. The rivets may preferably be designed as hollow rivets which can 
be deformed and thus riveted with appropriate dies or swages, provided on 
the injection mold. 
In another preferred embodiment of the invention the chip may be attached 
to the label by simply inserting its contact bumps into corresponding 
openings in the label. 
The chip may, however, also be glued to the label or may be soldered 
thereto. Further, the chip may also be applied to the label under the 
action of a spring. This may be made particularly if the label is a 
metallic foil. 
If metallic foils are used, the chip is simultaneously screened against 
electromagnetic fields. 
The metallic foil may comprise contact segments, thus enabling to use the 
metallic foil itself for the generation of the contact area. 
The particular design of the segmented contact area may be effected by 
laser cutting, edging or other conventional methods as printing, galvanic 
deposition, vapor deposition or the like. 
According to a further embodiment of the invention the contact bumps are 
plastically deformed during the printing of the contact area. 
In some embodiments of the invention the chip is mounted to a carrier 
element. The carrier element may provide a mechanical of thermal 
protection of the chip during the subsequent injection process. 
In preferred embodiments of the invention the label is connected with a 
second, parallel label, connected together in a sandwich arrangement. 
If the electrical connection between the chip and the contact area on the 
surface of the composite component is made by soldering, it is 
particularly preferred to effect the soldering under the action of the 
heat being dissipated anyway by the hot molten plastic material injected 
into the cavity. The soldering is, thus, effected by itself without the 
necessity of using separate soldering equipment. 
If the contact shall be made by riveting, it is preferred to arrange an 
appropriate riveting tool or swage on one of the mold portions in order to 
enable riveting during the production of the components, for example 
during the production of smart cards or PCMCIA cards. 
It goes without saying that the features, mentioned before and those that 
will be explained hereafter, cannot only be used in the particular given 
combination but also in other combinations or alone without departing from 
the scope of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
In FIG. 1 reference numeral 1 designates a composite component according to 
the invention, for example a smart card of the type described at the 
outset. 
The composite component is provided with an imprint 4 on its upper surface 
2 and/or on its lower surface 3. 
A contact area 5 is provided at a predetermined location of the composite 
component. The contact area 5 conventionally consists of contact segments, 
as schematically shown in FIG. 1. 
In component 1 first surface 2 and/or second surface 3 may be configured by 
a label. A chip having an electronic circuitry is embedded in component 1. 
The chip is electrically connected to contact area 5 on surface 2 of the 
label. 
The remaining area between the labels and the chip is repleted with a 
plastic material mass. 
The injection process shall now be briefly explained with reference to 
FIGS. 2-4. FIG. 2 schematically depicts a plastic material injection mold 
30 having a first, left mold portion 31 as well as a second, right mold 
portion 32. The corresponding installations for opening and closing, 
respectively, mold 30, as well as assemblies for feeding plastic material 
22 to mold 30 are not shown for the sake of clarity. A handling system for 
loading and unloading, respectively, mold 30 is schematically indicated 
with reference numeral 45. 
As can be seen from FIG. 2 a composite component 1 having been manufactured 
during the preceding cycle is still arranged in mold 30. 
Mold 30 is now opened by displacing mold portions 31 and 32 along arrows 
33, 34 in a lateral direction. Concurrently, an arm 46 of handling system 
45 is introduced into the opening gap between mold portions 31, 32, the 
handling system 45 being a structural part of a robot. In the shown 
example only the front portion is depicted having gripping or other 
attracting components for loading a semi-finished element 1' on the one 
side and for unloading a manufactured component 1 on the other side. Arm 
46 is provided with two gripping elements being displaceable with respect 
to each other along double arrow 44, as indicated by numerals 48 and 49 
and may be provided with additional attracting elements. 
Semi-finished product 1' consists of two labels 20, 21 being connected at 
one end thereof by means of glue points 25, 26. Chip 13 adjoins label 20 
and is, further, connected to opposing label 21 by means of another glue 
point 27. 
Hence, labels 20, 21 and chip 13 are configured as a sandwich that may 
easily be handled due to the connection of the aforementioned elements 
through glue points 25-27. The sandwich may be held by arm 46 or gripping 
element 48, respectively and may be inserted into cavity 38 between mold 
portions 31, 32 along arrow 36. 
During that period of time the composite component having been manufactured 
during the preceding cycle is still located within the cavity of second 
mold portion 32. As soon as arm 46 has come to its terminal position 
between the two mold portions 31, 32 (FIG. 3) gripping element 48 will be 
displaced in a direction towards left mold portion 31 for transferring 
semi-finished 1' into the cavity 39 in the left mold portion. Such 
transfer may be assisted by blowing air. 
Concurrently, an ejector 47 in the right mold portion 32 is actuated, thus 
ejecting component 1 from cavity 37 within right mold portion 32. Ejected 
component 1 is picked up by gripping element 49 on arm 46 which, for that 
purpose, is slightly displaced in the direction of second mold portion 32 
as shown in FIG. 4. The transfer of component 1 may be assisted by blowing 
or sucking air. 
Gripper elements 48, 49 are then again moved together and arm 46 is then 
displaced along arrow 35 for entirely leaving the gap between mold 
portions 31, 32. Ejector 47 is retracted and mold portions 31, 32 may be 
closed as soon as arm 46 has entirely left gap 38. 
In a subsequent phase following the phase of FIG. 4 cavity 38 between mold 
portions 31, 32 is repleted by injecting molten plastic material. The 
molten plastic material exerts a pressure on chip 13 and presses same 
against the inner surface of mold 30. 
The structure of composite component shall now be described in relation to 
the subsequent Figures. Like elements are insofar designated with the same 
reference numerals. 
Chip 13 adjoins the inner surface of label 20. Label 20 is provided with 
three openings 9, 10, 11. Contact bumps 17, 18, 19 being provided on the 
surface of chip 13 extend through openings 9, 10, 11. During the injection 
molding these contact bumps 17, 18, 19 or elements had been riveted onto 
the exterior surface 2 of label 20 so that chip 13 was simultaneously 
mechanically attached to label 20 during the injection. 
Contact area 5 consists of three contact segments 6, 7, 8 which have been 
applied over contact bumps 17, 18, 19 subsequently by printing an 
electrically conductive paste thereon, as shown in FIG. 5. However, this 
printing may already have occurred previously. 
FIG. 6 is an illustration on further enlarged scale showing how the contact 
bumps 17, 18, 19 had been plastically deformed and, hence, riveted to 
label 20 through the closing of mold portion 31, 32 during the injection 
process. 
As can be seen from FIG. 6, contact bumps 17 prior to the beginning of the 
injection process have an essentially hollow cylindrical shape and extend 
outwardly through corresponding openings 9 in label 20. 
Whereas in the embodiment of FIG. 5 the contact segments had been 
established after the riveting, in the embodiment of FIG. 6 the surface of 
label 20 has been previously metallized in a desired pattern for 
generating the various contact segments of contact area 5. 
According to FIG. 6 an appropriate die or swage 24 being displaceable 
relative to mold portion 31 enters into the cavity of contact bump 17 
during the injection process and deforms the hollow cylindrical wall 
during further closing of the tool, thus generating the final shape of the 
rivet, as indicated by dashed line 12 in FIG. 6. The external edge of 
contact bump 17 is, thus, riveted on contact segment 6, concurrently 
ensuring a permanent and safe contact between chip 13 and contact segment 
6. 
Mold portion 31 is provided with one swage or die for each of the contact 
bumps so that all of the contact bumps are simultaneously riveted during 
the closing of mold portions 31, 32. It goes without saying that the shape 
of contact bumps 17, 18, 19 may vary during the riveting and that die 24 
may be designed slightly conically in order to assist a widening and a 
plastic deformation of the hollow rivet. 
It is possible to withdraw die 24 after the riveting step actively, for 
example with a hydraulic unit. However, also a passive retraction may be 
effected through the pressure exerted by the plastic material mass on chip 
13, resulting in a certain plastic post-deforming and widening of the 
rivet so that only minor depressions result in the center of the rivet, as 
indicated in FIG. 6 by dashed line 12. 
In the embodiment of FIGS. 5 and 6 the fastening of chip 13 on label 20 may 
be effected by simply extending contact bumps 17, 18, 19 through apertures 
or openings 9, 10, 11 in label 20. 
FIG. 7 shows a modified embodiment. 
This embodiment essentially corresponds to those briefly explained 
previously with regard to FIGS. 2-4. Chip 13 adjoins inner surface 23 of 
label 20. Its contact bumps 17, 18, 19 extend through openings 9, 10, 11 
in label 20 and protrude therefrom. 
Contact bumps 17, 18, 19 are designed as cones or tips. Chip 13 is 
connected to opposing label 21 by means of a glue point 27. 
In the course of manufacture label 20 is first provided with the openings 
9, 10, 11 and chip 13 is then attached thereto by pushing contact bumps 
17, 18, 19 through openings 9, 10, 11. This is preferably made from above 
when label 20 is arranged on a support. One can then apply glue points 25, 
26, 27 and then place second label 21 thereover. 
According to the embodiments of FIGS. 5 and 7 the contact area is generated 
immediately thereafter on label 20. 
FIG. 8 shows another embodiment of the invention. 
In contrast to the embodiments described before, label 20 having chip 13 
thereon, consists of a metal. 
Label 20 is provided with a recess 50, the edges of label 20 defining 
recess 50 wherein are directed inwardly to form a sleeve-shaped extension 
51. Wall surfaces 52, 53 of sleeve-shaped extension 51 receive between 
them chip 13 with front surfaces 54, 55. Contact bumps 17, 19 are provided 
on front surfaces 54, 55 of chip 13 such that chip 13 with its contact 
bumps may elastically be received between wall surfaces 52, 53 of 
extension 51. 
As label 20 is configured as a metal foil, it has a significantly higher 
stability so that the elasticity of extension 51 is sufficient for holding 
chip 13 safely during the subsequent injection process. 
Contact bumps 17, 19 are provided with an easily melting soldering material 
and opposing wall surfaces 52, 53 may be treated the same way. 
During the subsequent injection process the soldering material is molted 
under the action of the heat dissipated by the injected hot liquid plastic 
material. 
The space between recess 50 in label 20 and chip 13 is entirely repleted by 
plastic material 22 during injection. 
Metal foil 20 has preferably been pre-treated prior to attaching chip 13 
thereto. For example, individual printed connector paths or contact 
segments may have been generated. The final separation between the contact 
segments of the contact area from the remaining portion of label 20 is 
preferably effected only after the termination of the injection so that 
the respective pieces will not fall apart. As an alternative, one could 
affix them previously to an adhesive band or the like. 
After the composite component is manufactured, the individual contact 
segments may be separated from each other for example by laser cutting or 
etching or by mechanical methods like cutting or milling. 
In the embodiment of FIG. 8 the composite component is provided with one 
label only whereas the surface 3 on the lower side of the component is 
configured by the plastic material 22 itself. 
According to another embodiment of FIG. 9 chip 13 is again attached to the 
inner surface 23 of metal label 20 via its contact bumps 17, 19. 
In contrast to the embodiment described with respect to FIG. 8, however, 
metal label 20 is configured along a plane so that chip 13 with its 
contact bumps 17, 19 directly adjoins inner surface 23 of label 20. In 
order to enable a previous attachment of chip 13 to label 20 a glue point 
56 is provided between chip 13 and label 20. 
According to another embodiment of FIG. 10 chip 13 is surrounded by a 
cap-shaped carrier body. Carrier body 40 has an edge 41 extending parallel 
to label 20 and being attached to label 20 via glue points 57, 58. Chip 13 
is located below an aperture 50 in label 20 and is entirely surrounded by 
carrier body 40. A gap between carrier body 40 and chip 13 is repleted 
with plastic material 22 during injecting. 
Chip 13 had previously been attached to bottom 4 via a glue point 49. 
For production purposes aperture 15 is first applied to label 20 and chip 
13 is then attached to bottom 42 of carrier body 40 by means of the glue 
point 59. Its contact bumps 17, 19 are extending outwardly. Carrier body 
40 is now glued with its edge 41 to inner surface 23 of label 20 by means 
of glue points 57, 58. 
During subsequent injection plastic material 22 flows through the remaining 
gaps between edge 41 and label 20 and entirely repletes the remaining 
cavity so that a flush transition is obtained in the area of aperture 50. 
Contact bumps 17, 19 having a rectangular cross section in the embodiment 
of FIG. 10, extend somewhat outwardly. 
During injection glue points 57, 58, 59 are plastified. After the injection 
contact segments 6, 7 are generated by printing an electrically conductive 
paste thereon. 
Another embodiment of the invention is shown in FIG. 11. 
Label 20 is again configured as a metal foil having an aperture 50 for chip 
13. Chip 13 is provided at its front surface with grooves 61, 62 by means 
of which chip 13 may be elastically inserted into aperture 50 being 
somewhat smaller. Chip 13 is, hence, elastically held. For the sake of 
clarity the illustration of FIG. 11 is somewhat exaggerated. 
Contact bumps 17, 19 of chip 13 extend outwardly. 
During the injection a stamp 60 of mold portion 31 presses chip 13 into 
plastic material 22 until chip 13 is essentially flush with label 20. 
This elastic attachment of chip 13 to label 20 together with its subsequent 
impression during injection makes an easy production possible. 
It goes without saying that label 20 instead of being made from a metal 
foil may also be made from a plastic material foil, provided the plastic 
material foil has sufficient rigidity. 
Further embodiments of the invention will be described hereafter with 
respect to FIGS. 12-15. 
In FIG. 12, very much like in FIG. 10, chip 13 is surrounded by a 
cup-shaped carrier body 40. 
However, in contrast to the embodiment of FIG. 10 cup-shaped carrier body 
40 is not affixed with its edge 41 to inner surface 23 of label 20. 
Instead, edge 41 rests on the outside of label 20 and on the edge of 
aperture 50. Chip 13 and edge 41 of carrier body 40 are essentially flush 
to surface 2 of label 20. 
Carrier body 40 is subdivided into individual contact segments or contact 
flanges 62, 63 which, according to FIG. 12, are separated in their center 
by means of an isolation 66. At this instance a segmented metallic carrier 
body 40 may be used. However, carrier body 40 is preferably made of 
plastic material and may be metallized along segments. 
Carrier body 40 itself helps for establishing an electrically conductive 
connection between contact bumps 17, 19 engaging bottom 20 of carrier body 
40. Hence, edges 41 of carrier body 40 may by themselves be used as a 
contact area or may subsequently be provided with an electrically 
conductive coating. 
Although the carrier body will protrude from label 20 after having been 
inserted into aperture 50, it may be arranged subsequently by means of the 
elevated temperatures within the cavity to become flush with label 20. 
FIG. 13 shows a modified embodiment as compared with that of FIG. 12. 
In contrast to the embodiment of FIG. 12 the cup-shaped carrier body 40 has 
a label 20 attached to inner surface 23. For that purpose, label 20 had 
previously been provided with openings 9, 10, 11 as in FIG. 7. Contact 
bumps 17, 18, 19 of chip 13 extend through openings 9, 10, 11. Chip 13 is 
attached to inner surface 23 of label 20 by means of carrier body 40 
because edge 41 is glued to label 20. 
Chip 13, therefore, is entirely shielded against hot plastic material 22 
and also mechanically protected during injection. FIG. 14 shows another 
modified embodiment. Again, an aperture 50 is made in label 20 for 
allowing to insert a flange-shaped carrier body 50 having an inwardly 
directing extension 51. Chip 13 with its contact bumps 17, 19 is held 
between wall surfaces 52, 53 of extensive 51, similar to the arrangement 
of FIG. 8. 
Carrier body 40 with its outer edge 41 rests on the rim of aperture 50 in 
label 20. The gap between aperture 50, chip 13 and carrier body 40 is 
again entirely repleted with plastic material 22, resulting in a flush 
termination in the level of label 20. 
Carrier body 40 may also be elastically held within aperture 50. For that 
purpose aperture 50 may be dimensioned somewhat smaller than extension 51. 
A last embodiment of the invention is shown in FIG. 15. Carrier body 40, 
similar to the embodiment of FIG. 12, is frusto-conically shaped and, in 
contrast to the embodiment of FIG. 12, rests with its edge 41 on outer 
surface 2 of label 20, namely on the rim of aperture 50. 
Carrier body 40 is again subdivided into individual contact flanges being 
electrically conductive and having an inner surface for connection with 
chip 13 on its contact bumps 17, 19. The connection may be made e.g. by 
soldering. Carrier body 40 with its edge or color 41 may again be 
elastically held in aperture 50 of label 20 by clipsing which, however, is 
not shown in FIG. 15. As an alternative, carrier body 40 may be attached 
by gluing. 
After the termination of the injection, surface 2 of label 20 is provided 
with a contact area in that an electrically conductive paste is printed 
thereon and connecting contact flanges 62, 63 of carrier body 40 with 
contact bumps 17, 19 of chip 13.