A thin electronic card having an integrated circuit chip and battery and a method of producing same

Abstract: A method for producing an electronic card by printing an electroconductive pattern and a first electrode surface of a battery on a first cover sheet, applying a battery activator onto the first electrode surface, resting an electrolyte-impregnated separator onto the first electrode surface, fixing an IC chip to the electroconductive pattern in a predetermined position, printing a second electrode surface of the battery on a second cover sheet, applying a battery activator onto the second electrode surface, and lapping and sticking the first and second cover sheets together and cutting them into a predetermined size.

Description: The present invention relates to a thin electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip, as well as to a method for producing same. Recently, with the tendency to thinning of small-sized electronic devices, there have been developed items such as card-type electronic calculators having an integrated circuit chip between resin sheets and an electrical battery for supplying electrical power to the integrated circuit chip, as well as thin electronic devices such as IC cards having a memory function. Heretofore, a button- or coin-shaped battery has been used in such small-sized electronic devices. The maximum thickness of such thin electronic devices is defined to be 0.80 mm by JIS. However, the use of a button- or coin-shaped battery in a thin electronic device has heretofore made it difficult to fabricate the electronic device within the rated maximum thickness imposed by this standard. Recently, moreover, applications of such IC cards have been considered, for example, to theft detecting systems and automatic goods sorting systems, as disclosed in Japanese patent publication number 22997/84. Since it is necessary to provide a large number of IC cards as consumables, there has arisen the necessity of mass-producing IC cards inexpensively. In the prior art, the body of the thin electronic device and the battery are produced separately and thereafter the battery is inserted into the body. This method, however, is very troublesome and low in productivity, leading to increased unit cost. JP-A-6054173 discloses a thin electronic card corresponding to the precharacterising part of claim 8. In this prior art an integrated circuit and a battery power source therefor are disposed in side by side relation on one face of the substrate of the card. It is an object to provide a card-type electronic device and its manufacturing method in which the mounting of the battery and I-C chip on the card substrate is improved. According to one aspect of the present invention there is provided a method of producing an electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip, comprising: a first printing step (13) of forming by printing an electroconductive pattern (4) comprising a first connecting conductor and a first electrode surfaces (4A₁) of a battery (5) on a first cover sheet (1); a first application step (14) of applying a battery activator onto said first electrode surface (4A₁); a resting step (17) of resting an electrolyte-impregnated separator (15) onto said first electrode surface; a fixing step (21) of fixing an IC chip (6) to the connecting conductor of said electroconductive pattern (4) in a predetermined position; a second printing step (25) of forming by printing a second connecting conductor and a second electrode surface (4B₁) of said battery (5) on a second cover sheet (2); a second application step (26) of applying a battery activator onto said second electrode surface; and a cutting step (30) of connecting the second connecting conductor with the I-C chip, lapping and sticking said first and said second cover sheet together to hold said I-C chip between the first and the second cover sheet (1,2) and cutting them to a predetermined size. According to another aspect of the present invention there is provided a method of producing an electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip, comprising the steps of: printing an electroconductive pattern (4) comprising connecting conductors and first (4A₁) and second (4B) electrode surfaces of a battery (5) onto integrally-formed first and second cover sheet portions; applying an anodic active material and a cathodic active material onto said first and second electrode surfaces (4A₁, 4B), respectively; fixing an IC chip (6) to said connecting conductors of said electroconductive pattern in a predetermined position; resting an electrolyte-impregnated separator (5C) onto one of said first and second electrode surfaces; and folding said first and second cover portions so as to be superposed one upon the other to hold said I-C chip between the first and the second cover sheet (1,2) and cutting them to a predetermined size. According to a further aspect of the present invention there is provided a thin electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip including: a first cover sheet (1) with an electroconductive pattern (4) comprising a first connecting conductor and a first electrode surface (4A₁) of a battery (5) printed thereon; a second cover sheet (2) with a second connecting conductor and a second electrode surface (4B) of the battery (5) printed thereon; an anodic active material applied onto said first electrode surface (4A₁); a cathodic active material applied onto said second electrode surface (4B); a separator (5C) impregnated with electrolyte; an I-C chip (6) which is positioned between said first and said second cover sheet (1, 2); and said connecting conductors formed on said first and said second cover sheet (1, 2) connecting said first and second electrode surfaces with said I-C chip. said anodic active material and said cathodic active material being opposed to each other through the separator (5C), said first and said second cover sheets (1, 2) being laminated together to hold said I-C chip (6). As will become apparent from the following description, the invention can provide a card-type electronic device and its manufacturing method which enables the device to be thinner than the conventional and and makes it easy and low in cost to manufacture the device. The invention will be further described by way of non-limitative example with reference to the accompanying drawings, in which:- Figure 1 is a schematic explanatory view of a method for producing an information card according to the present invention; Figures 2(a), 2(b) and 2(c) are a plan view, a sectional side view and a separated side view respectively, of the information card; Figures 3(a) to (g) are plan views of the information card in the course of manufacturing steps; Figure 4 is an enlarged view of an IC chip;; and Figures 5(a) to (c) are process charts showing another embodiment of the present invention. Figure 1 is a schematic view for explaining the method for producing a card according to the present invention. An example of a concrete structure of the information card thereby produced is shown in the plan view of figure 2(a), the sectional view of figures 2(b) and the separated side view of figure 2(c). Patterns on the information card surface in the manufacturing steps of [I] to [V] are shown in figure 3. For example, as shown in the plan view of figure 2(a) and sectional view of figure 2(b), the information card comprises a back-side cover sheet (hereinafter referred to also as the first cover sheet) 1 and a surface-side cover sheet (also as the second cover sheet hereinafter) 2. In the card of this embodiment, an adhesive sheet 3 is stuck on the upper surface of the surface-side cover sheet 2 to display the kind of card. Between the first and the second cover sheet there are provided an electroconductive pattern 4, a flat battery 5 and an IC chip 6. For the purpose of reducing the thickness of the card, a hole 2A is formed in the second cover sheet 2 to accommodate the IC chip 6 when the first and the second cover sheet are lapped together. Part of the electroconductive pattern 4, which is connected to the IC chip 6, serves as a pair of antennas (dipole antennas) 4A₂ whose characteristic impedance changes according to the data stored in the IC memory, while wider area portions thereof serve as positive and negative electrode surfaces 4A₁, 4B₁. This change in impedance may, as is well known, be used by a reader device to read data stored in the IC memory. The antenna can also be used to receive data transmitted to the card. As best seen in figure 2(c), the battery 5 is formed by applying active materials 5A and 5B (Zn, MnO₂) of the battery in the state of a gel onto the electrode surfaces 4A₁ and 4B₁ which are formed by the printing technique or the like on the first and second cover sheets 1, 2, and then sandwiching an electrolyte-impregnated separator 5C in between the cover sheets 1 and 2. On the outer surface of the first cover sheet 1 there may be formed a magnetic film 7 according to ISO standards as in ordinary magnetic cards such as credit cards. An embodiment of the method of the present invention for producing a card as described above will be described hereinunder with reference to figure 1. In figure 1, reference numeral 11 denotes a band-like cover sheet (A) formed of polyethylene terephthalate (PET) or polypropylene (P.P) and having a thickness of about 50 µm. The cover sheet 11 is drawn off of a supply roll in the illustrated direction and fed to a magnetic stripe printing section, wherein a magnetic film area according to ISO standards is formed on the lower surface of the cover sheet 11(A). Numeral 13 denotes a screen printing section (A) for forming a wiring pattern on the upper surface of the cover sheet 11. In the screen printing section 13, a wiring pattern such as is shown in figure 3(a) is printed to the cover sheet 11, using an electroconductive coating material such as, for example, pasty carbon, copper which has been made pasty, or pasty mercury. The portion 4A₁ of this wiring patten represents an electrode surface [4A₁ in figure 2(c)] serving as a negative (-) pole of the battery in the information card, while the portion 4A₂ represents an electroconductive surface serving as antenna. Numeral 14 denotes an active material applying section for applying zinc (Zn) gel which acts as an activator in the battery to the portion 4A₁ which serves as an electrode surfaces as in figure 3(a), and in the portion indicated by rightwards oblique lines in figure 3(b), Zn gel 5A is applied onto the upper surface of the wiring pattern 4A₁ to a thickness of about 50 µm. Numeral 15 denotes a separator sheet in the battery which sheet is formed by kraft paper for example. The separator sheet 15, which is rolled, passes through an electrolyte impregnating section 16, whereby it is impregnated with electrolyte, eg, ZnCl₂. The thus electrolyte-impregnated separator 5C is cut into a predetermined size in a cutting section 17, then in a separator sticking section 18 it is placed on the electrode surface 4A₁ of the wiring pattern, as shown in figure 3(c). By the above continuous steps there is constituted the first cover sheet 1 (surface A). Then, in a mask mounting section 19, as shown in figure 3(c), a frame 8 is stuck to the first cover sheet having the surface A so as to slightly raise the peripheral portion of the wiring pattern. Further, in a hardener applying section 20, a small amount of a hardener 9 is applied to the first cover sheet 1 at the position at which the IC chip 6 is to be fixed. At this time, a polyester-based hot melt adhesive is screen-printed to the outer peripheral portion of the electrode surface 4A₁. Numeral 21 denotes an IC chip packaging machine. IC chips 6 fed one by one from the IC chip packaging machine 21 are each pushed against the wiring pattern in a predetermined position. For example, as shown in the enlarged view of figure 4, lead terminals of the IC chip 6 are formed as bumps 6A, which are pushed against the wiring pattern 4 in predetermined positions. Then, infrared ray is radiated from an infrared ray radiating section 22 to the pre-applied hardener 9 to thereby fix the first cover sheet 1 and the IC chip 6 together. Since the hardener 9 hardens and contracts upon radiation of infrared ray, the bumps 6A and the wiring pattern 4 make a good electrical contact. The cover sheet of the surface A shown in figure 3(d) with the IC chip 6, battery active material and separator formed thereon is then lapped with a cover sheet 23 which serves as the second cover sheet 2 and both are stuck together. More specifically, the cover sheet (B) (PET or P.P) 23, which is rolled, is drawn out in the arrowed direction and fed to a puncher 24, in which there are formed an aperture B₁ for the IC chip and apertures B₂ for antenna contact, as shown in figure 3(e). The aperture B₁ is formed at a position corresponding to the mounted position of the IC chip fixed to the cover sheet of the surface A as mentioned above, while the apertures B₂ are formed in the positions corresponding to the antenna areas (4A₂, 4A₂). The cover sheet (B) thus formed with the apertures B₁ and B₂ is then fed to a screen printing section (B) 25, in which an electroconductive wiring pattern such as that shown in figure 3(f) is printed to the cover sheet. The greater part of the wiring pattern is in corresponding relation to the electrode surface (4A₁) of the surface A, forming a positive (+) electrode surface [4B₁ in figure 2(c)] of the battery. Then, in an active material applying section (B) 26, for example zinc oxide 5B (ZnO₂) which is in the state of gel is applied as a depolarize to the electrode surface of the surface B to a thickness of about 50 µm to form the cover sheet of figure 3(g). Preferably, at this time, a polyester-based hot melt adhesive is screen printed also to the outer peripheral portion of the electrode surface (4B₁). This cover sheet (B) of the surface B and the foregoing cover sheet (A) of the surface A are lapped together and united, for example by heat-treating the two at 130°C for about 15 minutes or by an ultrasonic fusion-bonding technique, at station 27. At this time, the battery electrode surfaces are completely sealed by the hot melt adhesive. In this case, it goes without saying that both sheets should be lapped together and united for registration between the pattern on the surface A and that on the surface B and in such a position as to permit the IC chip 6 to be embedded in the aperture B₁. Numeral 28 denotes an adhesive tape, which is stuck to cover the apertures B₁ and B₂ of the cover sheet (B) which has been rendered integral with the other cover sheet by fusion-bonding for example. Lastly, the integral sheet member is cut into a predetermined size (eg, a size according to ISO standards) by means of a cutter 30 to obtain such information card as shown in figure 2. Although in the information card manufacturing method described above the cover sheets (11, 23) of the surfaces A and B which constitute the information card are fed separately, there may be used cover sheets (A) and (B) which are in a united state from the beginning. More specifically, as shown in figure 5(a), a cover sheet 31 serving as both surfaces A and B has a groove G which permits folding upwards and downwards with respect to a central line. The surface of the cover sheet 31 is divided into surfaces A and B on both sides of the groove G, and wiring patterns 4A and 4B are printed on the surfaces A and B, respectively, using an electroconductive coating material. As previously noted, Zn gel is applied to an electrode surface 4A₁ of the wiring pattern 4A, while ZnO₂ gel is applied to an electrode surface 4B₁ of the surface B. And as shown in figure 5(b), a separator 5C impregnated with electrolyte is put on the surface B, and apertures B₁ and B₂ are formed on the same surface. Further, an IC chip 6 is fixed to the wiring pattern on the surface A using a hardener as noted previously and there is formed such cover sheet as shown in figure 5(b). The wiring patterns on the surfaces A and B of this cover sheet are connected together through an electroconductive path 4C extending across the groove G. The cover sheet of figure 3(b) is folded along the groove G as shown in figure 3(c), to superpose the surfaces A and B together to form an information card. Also in this second embodiment there are used most of the devices used in the manufacturing method illustrated in figure 1. The second embodiment is advantageous in that the screen printing sections 13, 25 and the active material applying sections 14, 26 can be gathered at one place, thus permitting further simplification of the manufacturing system.

Claims: A method of producing an electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip, comprising: a first printing step (13) of forming by printing an electroconductive pattern (4) comprising a first connecting conductor and a first electrode surfaces (4A₁) of a battery (5) on a first cover sheet (1); a first application step (14) of applying a battery activator onto said first electrode surface (4A₁); a resting step (17) of resting an electrolyte-impregnated separator (15) onto said first electrode surface; a fixing step (21) of fixing an IC chip (6) to the connecting conductor of said electroconductive pattern (4) in a predetermined position; characterized in that it further comprises a second printing step (25) of forming by printing a second connecting conductor and a second electrode surface (4B₁) of said battery (5) on a second cover sheet (2); a second application step (26) of applying a battery activator onto said second electrode surface; and a cutting step (30) of connecting the second connecting conductor with the I-C chip, lapping and sticking said first and said second cover sheet together to hold said I-C chip between the first and the second cover sheet (1,2) and cutting them to a predetermined size. A method according to claim 1, wherein an antenna portion (4A₂) is also formed on the electroconductive pattern in said first printing step. A method according to claim 2, wherein said electroconductive pattern and said first and second electrode surfaces are formed using carbon paste in said first (13) and second (25) printing steps. A method according to claim 2 or 3, wherein the antenna portion of said electroconductive pattern constitutes a dipole antenna. A method according to any one of claims 1 to 4, wherein a paste of one of anodic and cathodic active materials is printed onto the first electrode surface in said first application step, and a paste of the other of those active materials is printed onto the second electrode surface in said second application step (26). A method according to any one of claims 1 to 5, wherein said resting step (17) comprises using kraft paper as said separator and impregnating said kraft paper with ZnCl₂ as electrolyte. A method of producing an electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip, characterized in that it comprises the steps of: printing an electroconductive pattern (4) comprising connecting conductors and first (4A₁) and second (4B) electrode surfaces of a battery (5) onto integrally-formed first and second cover sheet portions; applying an anodic active material and a cathodic active material onto said first and second electrode surfaces (4A₁, 4B), respectively; fixing an IC chip (6) to said connecting conductors of said electroconductive pattern in a predetermined position; resting an electrolyte-impregnated separator (5C) onto one of said first and second electrode surfaces; and folding said first and second cover portions so as to be superposed one upon the other to hold said I-C chip between the first and the second cover sheet (1,2) and cutting them to a predetermined size. A thin electronic card having an integrated circuit chip and an electrical battery for supplying electrical power to the integrated circuit chip including: a first cover sheet (1) with an electroconductive pattern (4) comprising a first connecting conductor and a first electrode surface (4A₁) of a battery (5) printed thereon; a second cover sheet (2) with a second connecting conductor and a second electrode surface (4B) of the battery (5) printed thereon; an anodic active material applied onto said first electrode surface (4A₁); a cathodic active material applied onto said second electrode surface (4B); a separator (5C) impregnated with electrolyte; an I-C chip (6); and said connecting conductors formed on said first and said second cover sheet (1, 2) connecting said first and second electrode surfaces with said I-C chip; said anodic active material and said cathodic active material being opposed to each other through the separator (5C); characterized in that said I-C chip is positioned between said first and said second cover sheet (1, 2); and said first and said second cover sheets (1, 2) being laminated together to hold said I-C chip (6). A thin electronic card according to claim 8, wherein an antenna portion (4A₂) is also printed on the electroconductive pattern (4). A thin electronic card according to claim 9, wherein said first, second electrode surfaces and said connecting conductor are formed by screen-printing carbon paste onto said first and said second cover sheets (1, 2). A thin electronic card according to claim 8, 9 or 10, wherein said anodic active material is formed by screen-printing MnO₂ paste onto said first electrode surface. A thin electronic card according to any one of claims 8 to 11, wherein said cathodic active material is formed by screen-printing Zn paste onto said second electrode surface. A thin electronic card according to claim 11 or 12, wherein the thickness of said anodic active material applied and that of said cathodic active material applied are in the range of 20 to 70 µm. A thin electronic card according to any one of claims 8 to 13 and having a thickness not larger than 1 mm.

Inventors: HIGUCHI SHIGETAKA, HORI TAKESHI, KASHIMA TSUNEHIRO, NISHI YOSHIO, SHIMIZU HIDETOSHI, YASUDA AKIO, HIGUCHI, SHIGETAKA, HORI, TAKESHI, KASHIMA, TSUNEHIRO, NISHI, YOSHIO, SHIMIZU, HIDETOSHI, YASUDA, AKIO
Applicants: SONY CORP, SONY CORPORATION
Application year: 1989
Main classification: G06K19
IPC codes: H01M2, H01M6, G06K19, B42D15, B32B37