Patent Description:
In recent years, in order to meet the demands for high functionality, multi-functionality, enhancement in security performance, and the like, it is often the case that a substrate on which electronic components such as an IC (Integrated Circuit) chip as a variable information recording medium having a large capacity, an antenna circuit for receiving electricity and signals from the outside, a display part for displaying information, and a sensor part for detecting a fingerprint or the like are mounted is incorporated into a card.

As a method for incorporating, into the card, the substrate on which the electronic components are mounted, known is a method in which front and rear surfaces of the substrate are coated with synthetic resin; a method in which a synthetic resin sheet and a fiber sheet are laminated on front and rear surfaces of the substrate and the resultant laminate is subjected to hot pressing; or the like. In addition, as other manufacturing method, also known is a method in which synthetic resin sheets on front and rear surfaces thereof are bonded with an adhesive.

Whereas a thickness of a general card is approximately <NUM>, a thickness of an electronic component such as an IC chip is approximately <NUM> to <NUM> and further, a thickness of a substrate is also approximately <NUM>. Therefore, on a surface pf the IC card including these, a projecting portion is formed due to the thickness of the electronic component such as the IC chip, thereby deteriorating flatness and smoothness. In addition, if an external force is exerted on the projecting portion formed by the electronic component, the problem in that the electronic component is easily broken arises. Furthermore, appearance and printability of the IC card are impaired, thereby also leading to the problem in that an appearance commercial value is reduced.

Therefore, as a method for incorporating, into a card, a substrate on which an electronic component such as an IC chip is mounted while the above-mentioned problems are solved, for example, as described in <CIT> (Patent Literature <NUM>), known is a method in which by previously providing a depressed part or a hole for a paper layer (spacer layer) covering a surface of the substrate on which the electronic component is mounted, a thickness of the electronic component is absorbed. However, in the incorporating method described in Patent Literature <NUM>, it is required to change a shape and a placement position of the depressed part or the hole of the paper layer in accordance with a shape and a placement position of the electronic component on the substrate, thereby leading to the problem in that extremely burdensome processes are required and costs are also increased.

In addition, as a method for absorbing the thickness of the electronic component without providing the depressed part or the hole for the spacer layer or the like, for example, as described in <CIT> (Patent Literature <NUM>), known is a method in which by covering, with an adhesive layer (hot melt layer) having a predetermined thickness, the surface of the substrate on which the electronic component is mounted, the thickness of the electronic component is absorbed. However, in the incorporating method described in Patent Literature <NUM>, since the adhesive layer (hot melt layer) on the electronic component on the surface of the substrate is melt once, there arises the problem in that due to solidification speed unevenness upon curing resin, a sink is caused, a sufficient degree of flatness cannot be thereby obtained, or warpage is easily caused. In addition, there is a risk of damaging the electronic component due to an influence of heat, thereby also leading to the problem in that an electronic component to be used is limited only to an electronic component having heat resisting properties to some extent.

Furthermore, as other method for absorbing the thickness of the electronic component without providing the depressed part or the hole for the spacer layer or the like, for example, as described in <CIT> (Patent Literature <NUM>) and <CIT> (Patent Literature <NUM>), known is a method in which by covering, with fibers which are impregnated with molten resin or a fiber sheet such as paper and woven fabric, a surface of the substrate on which an electronic component is mounted, the thickness of the electronic component is absorbed.

In the method described in each of Patent Literatures <NUM> and <NUM>, since the thickness of the electronic component is absorbed by the fibers or the fiber sheet, as compared with the case in which only the adhesive layer (hot melt layer) is used, a local sink due to the solidification speed unevenness upon curing the resin is hindered from occurring, thereby enhancing flatness of the card and also enhancing a mechanical strength such as a bending strength. However, in the method described in each of Patent Literatures <NUM> and <NUM>, since the resin with which the fibers or the fiber sheet is impregnated is in a molten state, shrinkage unevenness of the fibers or the fiber sheet is caused or promoted due to the solidification speed unevenness upon curing the resin, thereby resulting in the problem in that warpage of the card becomes large. In particular, there arises the problem in that when the electronic component or the substrate on which the electronic component is mounted is displaced to either one of a front side or a rear side of the card, the warpage of the card tends to become further large.

Therefore, objects of the present invention are to provide a resin card medium which has a substrate having an electronic component or electronic components such as an IC chip or IC chips or like thereinside, has extremely high flatness (for example, with a warpage amount suppressed) and high smoothness (for example, with a depth of a local depressed part suppressed) which are attained by ordinary hot pressing molding without providing a spacer layer or the like having a depressed portion or a hole for absorbing thicknesses of the substrate and the electronic component or electronic components, is excellent in appearance and printability of the card, and has high appearance commercial value; and a manufacturing method therefor.

The present inventors, et al. have repeated eager researches as to a mechanism which causes a sink and warpage of a resin card medium which has a substrate having mounted thereon an electronic component or electronic components such as an IC chip or IC chips or the like, due to solidification speed unevenness upon curing resin. As a result, the present inventors, et al. have found out that using plastic fibers, instead of molten resin, and conducting hot pressing at a temperature which is a softening point or more of the plastic fibers and less than a melting point of the plastic fibers are extremely effective in suppressing solidification speed unevenness upon curing resin. Furthermore, the present inventors, et al. have found out that using mixed paper whose plastic fibers are mixed with plant fibers moderately suppresses a release of a residual stress inside the card, which is caused by the solidification speed unevenness or the like, and as a result, the warpage of the card can be effectively prevented, hence leading to the completion of the present invention.

In other words, according to the present invention, a resin card medium laminated body before pressing is prepared by laminating a substrate having one electronic component or two or more electronic components installed on one side of the substrate on a first plastic finishing sheet, with the one side of the substrate, on which the electronic component or electronic components are installed, facing upward; and laminating, on the substrate, mixed paper constituted of plastic fibers, which are constituted of copolymerized polyester resin such as PET resin, and plant fibers, and the resin card medium laminated body is subjected to hot pressing at a temperature which is a softening point or more of the plastic fibers and less than a melting point of the plastic fibers, thereby providing a resin card medium whose card warpage amount in conformity with an ISO/IEC <NUM>:<NUM> standard is <NUM> or less, and besides the ISO standard, a depth of a card local depressed part of the resin card medium is less than <NUM>.

In the resin card medium of the present invention, on the substrate on the side on which the electronic component or electronic components such as an IC chip or IC chips or the like are mounted, the mixed paper constituted of the plastic fibers which are constituted of the copolymerized polyester resin such as the PET resin and the plant fibers is laminated, and the card medium laminated body which includes the substrate having the electronic component or electronic components mounted thereon and the mixed paper is subjected to the hot pressing at the temperature which is the softening point or more of the plastic fibers in the mixed paper and less than the melting point thereof, thereby conducting compression-molding.

Since the temperature upon hot pressing is managed at the temperature which is the softening point or more of the plastic fibers constituted of the copolymerized polyester resin such as the PET resin in the mixed paper and less than the melting point thereof, the plastic fibers in the mixed paper neither melt nor a sink and warpage of the card medium are caused due to solidification speed unevenness of the molten plastic. In other words, it has been found out that a sink and warpage of the card medium caused due to curing speed unevenness of the softened plastic fibers are much smaller than a sink and warpage of the card medium caused due to solidification speed unevenness of molten plastic.

In addition, as a main factor which causes the warpage of the resin card medium after hot pressing molding, it is considered that an internal stress is caused in the card medium due to the solidification speed unevenness upon curing the resin, and the internal stress is released after the molding, resulting in the warpage of the resin card medium.

Since in the resin card medium of the present invention, the plant fibers whose shape, nature, and the like hardly change even if an influence of heat is exerted thereon are contained in the mixed paper, flowing of the softened resin is inhibited, and even if a residual stress in the card is caused due the curing speed unevenness or the like of the plastic fibers constituted of the copolymerized polyester resin such as softened PET resin or the like, the plant fibers serve as a reinforcing material and deformation of the card is restrained, and as a result, the release of the residual stress is prevented, thereby preventing the warpage and the deformation of the card.

In addition, since upon hot pressing, the mixed paper constituted of the plastic fibers constituted of the copolymerized polyester resin such as the PET resin and the plant fibers functions as a cushion material, the mixed paper absorbs a thickness or thicknesses of the electronic component or electronic components so as to keep flatness of the card medium after molding. As described above, in order for the mixed paper to surely absorb the thickness or thicknesses of the electronic component or electronic components, it is preferable that a percentage of a total of a thickness of the substrate and a thickness or thicknesses of the electronic component or electronic components to a thickness of the card medium after the hot pressing molding is adjusted to be <NUM>% or less, and it is more preferable that the percentage of the total of the thickness of the substrate and the thickness or the thicknesses of the electronic component or electronic components to the thickness of the resin card medium after the hot pressing molding is adjusted to be <NUM>% or less. As a result of this, extremely excellent flatness and smoothness in that the card warpage amount of the resin card medium of the present invention in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part thereof is less than <NUM> can be obtained.

In other words, the resin card medium of the present invention is defined in claim <NUM>.

In addition, in consideration of versatility thereof, it is preferable that a shape and dimensions of the resin card medium of the present invention are in conformity with the ISO/IEC <NUM>:<NUM> standard. As described above, the resin card medium of the present invention can have the extremely excellent flatness and smoothness in that the card warpage amount in conformity with the ISO standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part is less than <NUM>.

It is considered that in the resin card medium, the solidification speed unevenness of the molten plastic attributable to temperature unevenness and the curing speed unevenness of the softened plastic fibers are promoted also by displacement of a position of the substrate having the electronic component or electronic components mounted thereon from a middle position in a thickness direction to a front side or a rear side. However, since in the resin card medium of the present invention, the plant fibers whose shape, nature, and the like hardly change even if an influence of heat is exerted thereon are contained in the mixed paper, even when the temperature unevenness and the curing speed unevenness of the plastic fibers are caused by the placement of the substrate which is displaced to the front side or the rear side, the plant fibers serve as the reinforcing material, card deformation is thereby restrained, and as a result, the release of the residual stress is prevented, thereby preventing the warpage and the deformation of the card.

Therefore, even in a case in which the substrate having the electronic component or electronic components mounted thereon is located in the middle position in the thickness direction of the card medium in a longitudinal cross sectional view or in a case in which the substrate is located in such a way as to be displaced from the middle position to the front side or the rear side, the resin card medium of the present invention can have the extremely excellent flatness and smoothness in that the card warpage amount in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part is less than <NUM>.

When in the resin card medium of the present invention, electronic components, such as a display part, a fingerprint detection part, and the like, which need access to the outside are attached, by providing an opening part for one part of the plant fiber-containing resin layer (the mixed paper constituted of the plastic fibers and the plant fibers before the hot pressing molding) covering the substrate, the display part and/or the fingerprint detection part attached on the substrate can be exposed outside.

For the purpose of enhancing printability, glossiness, scratch resistance, and the like of a surface of the card, in the resin card medium of the present invention, on the plant fiber-containing resin layer which absorbs the thickness or thicknesses of the electronic component or electronic components, a second finishing layer may be further laminated. In addition, in consideration of a softening temperature at which the electronic component or electronic components are not damaged, durability and easiness of handling as a card material, and the like, it is preferable that each of the second finishing layer and/or the first finishing layer which is laminated on a rear surface of the substrate having the electronic component or electronic components mounted thereon is a plant fiber-non-containing resin layer containing no plant fibers, and further, a material of resin such as polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene terephthalate glycol-modified (PETG), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and the like can be used as the plant fiber-non-containing resin layer.

As described above, a method for manufacturing the resin card medium of the present invention which is extremely excellent in the flatness and the smoothness is defined in claim <NUM> or <NUM>.

Since the temperature upon hot pressing is managed at the temperature which is the softening point or more of the plastic fibers constituted of the copolymerized polyester resin such as the PET resin in the mixed paper and less than the melting point thereof, the plastic fibers in the mixed paper neither melt nor a sink and warpage of the card medium are caused due to solidification speed unevenness of molten plastic. In other words, it has been found out that a sink and warpage of the card medium caused due to curing speed unevenness of the softened plastic fibers are much smaller than a sink and warpage of the card medium caused due to solidification speed unevenness of the molten plastic.

In addition, in the method for manufacturing the card medium of the present invention, the plant fibers whose shape, nature, and the like hardly change even if an influence of heat is exerted thereon are contained in the mixed paper, flowing of the softened resin is inhibited, and even if a residual stress in the card is caused due the curing speed unevenness or the like of the plastic fibers constituted of the copolymerized polyester resin such as softened PET resin or the like, the plant fibers serve as a reinforcing material and deformation of the card is restrained, and as a result, the release of the residual stress is prevented, thereby preventing the warpage and the deformation of the card.

Furthermore, in the method for manufacturing the card medium of the present invention, since upon hot pressing, the mixed paper constituted of the plastic fibers constituted of the copolymerized polyester resin such as the PET resin and the plant fibers functions as a cushion material, the mixed paper absorbs a thickness or thicknesses of the electronic component or electronic components so as to keep flatness of the card medium after molding. As described above, in order for the mixed paper to surely absorb the thickness or thicknesses of the electronic component or electronic components, it is preferable that a percentage of a total of a thickness of the substrate and a thickness or thicknesses of the electronic component or electronic components to a thickness of the card medium after the hot pressing molding is adjusted to be <NUM>% or less, and it is more preferable that the percentage of the total of the thickness of the substrate and the thickness or the thicknesses of the electronic component or electronic components to the thickness of the resin card medium after the hot pressing molding is adjusted to be <NUM>% or less. As a result of this, it is preferable that a shape and dimensions of the resin card medium obtained by the manufacturing method of the present invention are in conformity with the ISO/IEC <NUM>:<NUM> standard, and further, the resin card has extremely excellent flatness and smoothness in that the card warpage amount of the resin card medium of the present invention in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part thereof is less than <NUM>.

In the method for manufacturing the card medium of the present invention, when electronic components, such as a display part, a fingerprint detection part, and the like, which need access to the outside are attached, by providing an opening part for one part of the plant fiber-containing resin layer (the mixed paper constituted of the plastic fibers and the plant fibers before the hot pressing molding) covering the substrate, the display part and/or the fingerprint detection part attached on the substrate can be exposed outside.

In the method for manufacturing the card medium of the present invention, for the purpose of enhancing printability, glossiness, scratch resistance, and the like, the step of laminating a second finishing layer on the mixed paper which absorbs the thickness or thicknesses of the electronic component or electronic components may be included. In addition, in consideration of a softening temperature at which the electronic component or electronic components are not damaged, durability and easiness of handling as a card material, and the like, it is preferable that each of the second finishing layer and/or the first finishing layer which is laminated on a rear surface of the substrate having the electronic component or electronic components mounted thereon is a plastic sheet containing no plant fibers, and further, a material of resin such as polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene terephthalate glycol-modified (PETG), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and the like can be used as the plastic sheet.

It is considered that in the resin card medium, the solidification speed unevenness of the molten plastic attributable to temperature unevenness and the curing speed unevenness of the softened plastic fibers are promoted also by displacement of a position of the substrate having the electronic component or electronic components mounted thereon from a middle position in a thickness direction to a front side or a rear side. However, since in the method for manufacturing the card medium of the present invention, the plant fibers whose shape, nature, and the like hardly change even if an influence of heat is exerted thereon are contained in the mixed paper, even when the temperature unevenness and the curing speed unevenness of the plastic fibers are caused by the placement of the substrate which is displaced to the front side or the rear side, the plant fibers serve as the reinforcing material, card deformation is thereby restrained, and as a result, the release of the residual stress is prevented, thereby preventing the warpage and the deformation of the card.

Therefore, in the method for manufacturing the card medium of the present invention, even when a thickness of the mixed paper which is laminated on the surface of the substrate on the side on which the electronic component or electronic components are installed before pressing is the same as a thickness of the first finishing sheet which is laminated beneath the surface of the substrate on a side opposite to the side on which the electronic component or electronic components are installed before pressing or is thicker than the thickness of the first finishing sheet, the resin card medium having the extremely excellent flatness and smoothness in that the card warpage amount in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part is less than <NUM> can be obtained.

According to the present invention, since the temperature upon hot pressing is managed at the temperature which is the softening point or more of the plastic fibers in the mixed paper and less than the melting point thereof, excellent effect in that the plastic fibers in the mixed paper neither melt nor a sink and warpage of the card medium are caused due to the solidification speed unevenness of the molten plastic can be obtained. In other words, excellent effect in that the sink and the warpage of the card medium caused due to the curing speed unevenness of the softened plastic fibers are much smaller than the sink and the warpage of the card medium caused due to the solidification speed unevenness of the molten plastic can be obtained.

According to the present invention, since the plant fibers whose shape, nature, and the like hardly change even if the influence of heat is exerted thereon are contained in the mixed paper, excellent effect in that flowing of the softened resin is inhibited, and even if the residual stress in the card is caused due the curing speed unevenness or the like of the plastic fibers, the plant fibers serve as the reinforcing material and deformation of the card is restrained, and as a result, the release of the residual stress is prevented, thereby preventing the warpage and the deformation of the card can be obtained.

In addition, according to the present invention, since upon hot pressing, the mixed paper constituted of the plastic fibers and the plant fibers functions as the cushion material, the mixed paper absorbs the thickness or thicknesses of the electronic component or electronic components so as to keep the flatness of the card medium after molding. As described above, in order for the mixed paper to surely absorb the thickness or thicknesses of the electronic component or electronic components, it is preferable that the percentage of the total of the thickness of the substrate and the thickness or thicknesses of the electronic component or electronic components to the thickness of the card medium after the hot pressing molding is adjusted to be <NUM>% or less, and it is more preferable that the percentage of the total of the thickness of the substrate and the thickness or the thicknesses of the electronic component or electronic components to the thickness of the resin card medium after the hot pressing molding is adjusted to be <NUM>% or less. As a result of this, according to the present invention, the resin card medium having extremely excellent flatness and smoothness in that the card warpage amount of the resin card medium of the present invention in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the ISO standard, the depth of the card local depressed part thereof is less than <NUM> can be obtained.

Hereinafter, a resin card medium and a manufacturing method therefor according to one embodiment of the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to Examples shown below, and a variety of modifications can be made without departing from the scope of the technical ideas of the present invention.

On a substrate <NUM> (with a product name "Polyimide Substrate") having a size of <NUM> × <NUM> and a thickness of <NUM>, one plastic pseudo chip A (<NUM>) having a <NUM>-mm-square size and a thickness of <NUM> and two plastic pseudo chips B (<NUM>) each having a <NUM>-mm-square size and a thickness of <NUM> were arranged in appropriate positions, thereby preparing a substrate <NUM> having the pseudo chips <NUM> and <NUM> installed thereon.

Next, one first finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of polyethylene terephthalate glycol-modified (PETG) was prepared; on the first finishing sheet <NUM>, the above-mentioned substrate <NUM> was laminated with a side, on which the pseudo chips <NUM> and <NUM> were installed, facing upward; three pieces of mixed paper <NUM> (with a product name "SC-<NUM>", manufactured by TOMOEGAWA CO. , having a thickness of <NUM> and a softening point of <NUM>) constituted of copolymerized polyester resin (PET resin) fibers and plant fibers were laminated thereon; and further, one second finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) was laminated thereon, thereby forming a card medium laminated body <NUM> in Example <NUM>.

The card medium laminated body <NUM> in Example <NUM> was heated at a temperature of <NUM> by a hot pressing machine and was thereby softened; the card medium laminated body <NUM> was held under a pressure of <NUM> MPa for five minutes; thereafter, the card medium laminated body <NUM> was further pressurized under a pressure of <NUM> MPa and was held for seven minutes; thereafter, with the pressure of <NUM> MPa retained, cooling was conducted therefor up to a room temperature; and the obtained resin card medium molded body was singulated into pieces each having a card shape, thereby preparing a resin card medium <NUM> in Example <NUM> whose dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard (<NUM>-thick × <NUM>-wide × <NUM>-high).

The same configuration as that in Example <NUM> except that three plastic pseudo chips C (<NUM>) each having a <NUM>-mm-square size and a thickness of <NUM> were used and arranged in appropriate positions on a substrate <NUM> was employed, thereby forming a card medium laminated body <NUM> in Example <NUM>.

The card medium laminated body <NUM> in Example <NUM> was subjected to hot pressing molding under the same conditions as those in Example <NUM>, thereby preparing a resin card medium <NUM> in Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

The same configuration as that in Example <NUM> except that a substrate <NUM> (with a product name "Polyimide Substrate") having a size of <NUM> × <NUM> and a thickness of <NUM> was used was employed, thereby forming a card medium laminated body <NUM> in Example <NUM>.

The same configuration as that in Example <NUM> except that three plastic pseudo chips A (<NUM>) each having a <NUM>-mm-square size and a thickness of <NUM> were used and arranged at mutual narrow intervals on a substrate <NUM> was employed, thereby forming a card medium laminated body <NUM> in Example <NUM>.

The same configuration as that in Example <NUM> except that instead of the three pieces of the mixed paper <NUM> (with the product name "SC-<NUM>", manufactured by TOMOEGAWA CO. , having the thickness of <NUM> and the softening point of <NUM>) constituted of copolymerized polyester resin (PET resin) fibers and plant fibers, three plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated and a second finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) was omitted was employed, thereby forming a card medium laminated body <NUM> in Comparative Example <NUM>.

The card medium laminated body <NUM> in Comparative Example <NUM> was subjected to hot pressing molding under the same conditions as those in Example <NUM> except that the heating condition was changed from <NUM> to <NUM> and the plastic laminated sheets <NUM> formed of the PETG were melted by a hot pressing machine, thereby preparing a resin card medium <NUM> in Comparative Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

The same configuration as that in Example <NUM> except that instead of the three pieces of the mixed paper <NUM> (with the product name "SC-<NUM>", manufactured by TOMOEGAWA CO. , having the thickness of <NUM> and the softening point of <NUM>) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers, three plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated and a second finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) was omitted was employed, thereby forming a card medium laminated body <NUM> in Comparative Example <NUM>.

The same configuration as that in Example <NUM> except that instead of the three pieces of the mixed paper <NUM> (with the product name "SC-<NUM>", manufactured by TOMOEGAWA CO. , having the thickness of <NUM> and the softening point of <NUM>) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers, three plastic laminated sheets <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated and a second finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) was omitted was employed, thereby forming a card medium laminated body <NUM> in Comparative Example <NUM>.

On a substrate <NUM> (with a product name "Polyimide Substrate") having a size of <NUM> × <NUM> and a thickness of <NUM>, three plastic pseudo chips C (<NUM>) each having a <NUM>-mm-square size and a thickness of <NUM> were arranged in appropriate positions, thereby preparing a substrate <NUM> having the pseudo chips <NUM> installed thereon.

Next, two first finishing sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of polyethylene terephthalate glycol-modified (PETG) were prepared; and with a side of the above-mentioned substrate <NUM>, on which the pseudo chips <NUM> were installed, facing upward, two plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated thereon, thereby forming a card medium laminated body <NUM> in Comparative Example <NUM>.

In other words, the card medium laminated body <NUM> in Comparative Example <NUM> has the same configuration as that of the card medium laminated body <NUM> in Comparative Example <NUM> except that the number of the first finishing sheets <NUM> laminated on a rear surface of the substrate <NUM> on which the pseudo chips <NUM> were installed and the number of the plastic laminated sheets <NUM> laminated on a front surface of the substrate <NUM> were both two.

Hot pressing molding conditions for the card medium laminated body <NUM> in Comparative Example <NUM> are the same as those for the card medium laminated body <NUM> in Comparative Example <NUM>.

In other words, the card medium laminated body <NUM> in Comparative Example <NUM> was subjected to hot pressing molding under the same conditions as those in Example <NUM> except that the heating condition was changed from <NUM> to <NUM> and the plastic laminated sheets <NUM> formed of the PETG were melted by a hot pressing machine, thereby preparing a resin card medium <NUM> in Comparative Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

The same configuration as that in Example <NUM> except that two plastic pseudo chips D (<NUM>) each having a <NUM>-mm-square size and a thickness of <NUM> were used and arranged in appropriate positions on a substrate <NUM> was employed, thereby forming a card medium laminated body <NUM> in Comparative Example <NUM>.

The card medium laminated body <NUM> in Comparative Example <NUM> was subjected to hot pressing molding under the same conditions as those in Example <NUM>, thereby preparing a resin card medium <NUM> in Comparative Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

The same configuration as that in Example <NUM> except that no plastic pseudo chips were arranged on a substrate <NUM> at all was employed, thereby forming a card medium laminated body <NUM> in Reference Example <NUM>.

The card medium laminated body <NUM> in Reference Example <NUM> was subjected to hot pressing molding under the same conditions as those in Example <NUM>, thereby preparing a resin card medium <NUM> in Reference Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

The same configuration as that in Reference Example <NUM> except that instead of the three pieces of the mixed paper <NUM> (with a product name "SC-<NUM>", manufactured by TOMOEGAWA CO. , having a thickness of <NUM> and a softening point of <NUM>) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers, three plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of polyethylene terephthalate glycol-modified (PETG) were laminated and a second finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) was omitted was employed, thereby forming a card medium laminated body <NUM> in Reference Example <NUM>.

The card medium laminated body <NUM> in Reference Example <NUM> was subjected to hot pressing molding under the same conditions as those in Reference Example <NUM> except that the heating condition was changed from <NUM> to <NUM> and the plastic laminated sheets <NUM> formed of the PETG were melted by a hot pressing machine, thereby preparing a resin card medium <NUM> in Reference Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

Two first finishing sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of polyethylene terephthalate glycol-modified (PETG) were prepared; a substrate <NUM> having no pseudo chips installed thereon at all was laminated thereon; and two plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated, thereby forming a card medium laminated body <NUM> in Reference Example <NUM>.

In other words, the card medium laminated body <NUM> in Reference Example <NUM> has the same configuration as that of the card medium laminated body <NUM> in Reference Example <NUM> except that the number of the first finishing sheets <NUM> laminated on a rear surface of the substrate <NUM> and the number of the plastic laminated sheets <NUM> laminated on a front surface of the substrate <NUM> were both two.

The card medium laminated body <NUM> in Reference Example <NUM> was subjected to hot pressing molding under the same conditions as those in Reference Example <NUM>, thereby preparing a resin card medium <NUM> in Reference Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

One first finishing sheet <NUM> (with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of polyethylene terephthalate glycol-modified (PETG) was prepared; one plastic pseudo chip A (<NUM>) having a <NUM>-mm-square size and a thickness of <NUM> and two plastic pseudo chips B (<NUM>) having a <NUM>-mm-square size and a thickness of <NUM> were arranged in appropriate positions thereon; and three plastic laminated sheets <NUM> (each with a product name "DIAFIX PG-WHI-FG", manufactured by Mitsubishi Plastics, Inc. , having a thickness of <NUM> and a melting point of <NUM>) formed of the polyethylene terephthalate glycol-modified (PETG) were laminated thereon, thereby forming a card medium laminated body <NUM> in Reference Example <NUM>.

In other words, the card medium laminated body <NUM> in Reference Example <NUM> has the same configuration as that of the card medium laminated body <NUM> in each of Comparative Examples <NUM> and <NUM> except that the card medium laminated body <NUM> has no substrate <NUM>.

The card medium laminated body <NUM> in Reference Example <NUM> was subjected to hot pressing molding under the same conditions as those in each of Comparative Examples <NUM> and <NUM>, thereby preparing a resin card medium <NUM> in Reference Example <NUM> whose shape and dimensions were in conformity with the ISO/IEC <NUM>:<NUM> standard.

As to warpage amounts of the resin card mediums, maximum distances from a plane of a surface plate were measured on all portions of protruding surfaces in conformity with the ISO/IEC <NUM>:<NUM> standard by using a laser displacement sensor (LK-<NUM>, manufactured by KEYENCE CORPORATION).

Surface depressions of the resin card mediums were measured by using the laser displacement sensor (LK-<NUM>, manufactured by KEYENCE CORPORATION) and were evaluated as follows.

A mark "o" indicates a case in which any depression such as a sink and a flaw whose depth was <NUM> or more was not present on a surface of a resin card medium (see <FIG>).

A mark "△" indicates a case in which one depression such as the sink and the flaw whose depth was <NUM> or more was present and one or more depressions such as the sink and the flaw whose each depth was <NUM> or more and less than <NUM> were also present on a surface of a resin card medium.

A mark "×" indicates a case in which two or more depressions such as the sink and the flaw whose each depth was <NUM> or more were present on a surface of a resin card medium (see <FIG>).

Manufacturing conditions and test results of the resin card mediums in the above-described Examples <NUM> to <NUM>, Comparative Examples <NUM> to <NUM>, and Reference Examples <NUM> to <NUM> are shown in the following Table <NUM>.

By comparing Examples <NUM> to <NUM> and Comparative Examples <NUM> to <NUM>, it has been found out from Table <NUM> that whereas when a total of thicknesses of each substrate and chips was changed by installing the pseudo chips having the different heights, in each of Comparative Examples <NUM> to <NUM> in which all of the substrate surface on the side on which the chips were installed was covered with the laminated sheets (plant fiber-non-containing resin layers not containing the plant fibers after the hot pressing molding) formed of the polyethylene terephthalate glycol-modified (PETG), the depressions due to the warpage, the sink, and the like whose each depth exceeded <NUM> were caused (see <FIG>), in each of Examples <NUM> to <NUM> in which all of the substrate surface on the side on which the chips were installed was covered with the mixed paper (plant fiber-containing resin layer containing the plant fibers after the hot pressing molding) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers, the depression due to the warpage, the sink, and the like whose depth exceeded <NUM> was not caused (see <FIG>).

Although the detailed mechanism of this is unknown, it is inferred that in the case of each of Comparative Examples <NUM> to <NUM>, since the plant fibers which inhibit flowing of the molten resin and function as a cushion material absorbing the thicknesses of the chips upon hot pressing or function to inhibit or suppress deformation of the card medium are not contained in the laminated sheets (plant fiber-non-containing resin layers) formed of the PETG, the depressions or the flaws due to the sink and the like caused by solidification speed unevenness and flowing unevenness of the molten resin and the like are caused on the card surface or a residual stress in the card is caused, and the residual stress is released after molding, thereby resulting in the large warpage of the card medium.

On the other hand, it is inferred that in the case of each of Examples <NUM> to <NUM>, the plant fibers which inhibit flowing of the softened resin and function as a cushion material absorbing the thicknesses of the chips upon hot pressing or function to inhibit or suppress the deformation of the card medium are contained in the mixed paper (plant fiber-containing resin layers), generation of the sink due to curing speed unevenness and flowing unevenness of the softened resin and the like is suppressed, and further, even if a residual stress is caused in the card, the plant fibers serve as a reinforcing material, deformation of the card is thereby restrained, and as a result, the release of the residual stress is suppressed and the warpage or the deformation of the card is thereby prevented.

Note that by comparing Example <NUM> and Example <NUM>, by comparing Comparative Example <NUM>, Comparative Example <NUM>, and Reference Example <NUM>, by comparing Example <NUM> and Comparative Example <NUM>, or by comparing Comparative Example <NUM> and Example <NUM>, it has been found out that a ratio of an occupancy area of the substrate to an area of the card medium hardly exerts an influence on flatness and smoothness of the card such as a magnitude of the warpage amount of the card and presence or absence of the generation of a local depressed part of the card.

In addition, by comparing Examples <NUM>, <NUM>, and <NUM> and Comparative Example <NUM>, it has been found out that in order to cause the mixed paper (plant fiber-containing resin layers containing the plant fibers after the hot pressing molding) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers to surely absorb the thicknesses of the pseudo chips and the substrate, it is required to adjust a percentage of a total of the thickness of the substrate and the thicknesses of the chips to a thickness of the card medium after the hot pressing molding to <NUM>% or less or more preferably, to <NUM>% or less. As a result of this, in the card medium in each of Examples <NUM> to <NUM>, extremely excellent flatness and smoothness in that the warpage amount of the card medium in conformity with the ISO/IEC <NUM>:<NUM> standard is <NUM> or less and besides the above-mentioned ISO standard, the depth of the local depressed part of the card is less than <NUM> can be obtained.

By comparing Reference Example <NUM> and Reference Example <NUM>, it has been found out that a position of the substrate in a thickness direction of the card medium is disposed in such a way as to be displaced to a front side or a rear side from a middle position, large warpage of the card medium is caused. It is inferred that since the thickness of the molten resin layer on the front side of the substrate and the thickness of the molten resin layer on the rear side thereof are different from each other, solidification speed unevenness, flowing unevenness, and the like are caused between the front side and the rear side of the substrate, and a residual stress caused in the card is released after molding, thereby resulting in the large warpage of the card medium.

On the other hand, by comparing Reference Example <NUM> and Reference Example <NUM>, it is inferred that in the case of Reference Example <NUM> in which the mixed paper (plant fiber-containing resin layers) constituted of the copolymerized polyester resin (PET resin) fibers and the plant fibers is used, since the plant fibers whose shapes, nature, and the like hardly change even if an influence of heat is exerted thereon are contained in the mixed paper, even if temperature unevenness, flowing unevenness, and curing speed unevenness of the copolymerized polyester resin (PET resin) fibers are caused due to the placement of the substrate displaced to the front side or the rear side, the plant fibers serve as a reinforcing material, deformation of the card is thereby restrained, and as a result, a release of the residual stress is prevented and the warpage and deformation of the card are thereby prevented.

Claim 1:
A resin card medium (<NUM>) comprising:
a substrate (<NUM>) having one electronic component or two or more electronic components installed on one side of the substrate (<NUM>),
a plant fiber-containing resin layer (<NUM>) being laminated on a surface of the substrate (<NUM>) on a side on which the electronic component or electronic components are installed and containing plant fibers and plastic fibers constituted of copolymerized polyester resin; and
a first finishing layer (<NUM>) being laminated on a surface of the substrate (<NUM>) on a side opposite to the side on which the electronic component or electronic components are installed, the first finishing layer (<NUM>) is a plant fiber-non-containing resin layer containing no plant fibers,
wherein
the plant-fiber-containing resin layer (<NUM>) absorbs the thickness or thicknesses of the electronic component or electronic components so as to keep flatness of the card medium, and
a percentage of a total of a thickness of the substrate (<NUM>) and a thickness or thicknesses of the electronic component or electronic components to a thickness of the card medium (<NUM>) is <NUM>% or less, characterised in that the thickness of the electronic component(s) is <NUM> to <NUM>, and the thickness of the substrate is approximately <NUM>.