Patent Description:
The card can be used to identify securely an individual using biometric analysis. The card has a processor with an internal memory and a biometric sensor. In use, a user connects the card to a scanner directly using physical electrical contacts or remotely using an electromagnetic interface. The memory often stores data for the purpose of encryption. The biometric sensor is intended for obtaining a physical trait of the user, namely fingerprint.

<CIT> shows a flexible electronic card that includes a card body, at least one cavity formed in the card body, and a fingerprint module configured to acquire a fingerprint of a user.

<CIT> shows a fingerprint sensing module that includes a fingerprint sensor device having a sensing array arranged on a side of the device, and connection pads for connecting the fingerprint sensor device to external circuitry and a fingerprint sensor device cover structure.

<CIT> shows a method of manufacturing a smart card.

<CIT> shows a smart card that comprises a top layer, a core layer of thermoset polymeric material, and a bottom layer comprising an Integrated Electronics Assembly.

<CIT> shows an electronic inlay that includes a circuit board, a plurality of circuit components attached to the circuit board, a bottom cover sheet, a top cover sheet, and a layer of thermosetting material between the bottom and top cover sheets.

<CIT> shows a fingerprint recognition radio-frequency (RF) smart card with an enhanced security function. The fingerprint recognition RF smart card has a CPU directly connected to a combination chip to execute a control operation, thereby preventing card information stored in the combination chip from being transmitted to the outside when the fingerprint information measured by a fingerprint sensor does not match the fingerprint information of a user.

<CIT> shows a passive secure data card that is provided with biometric authorization.

It is an object of this application to provide an improved card with fingerprint biometrics.

The application provides an inlay for a biometric card.

The inlay includes a first transparent overlay sheet, an antenna carrier sheet, a thickness compensation sheet, and a second transparent overlay sheet, and several components.

In detail, the antenna carrier sheet is provided next to the first transparent overlay sheet, and it includes a microcontroller opening, a contact module lead frame opening, and a finger sensor lead frame opening.

The thickness compensation sheet is provided next to the first transparent overlay sheet.

The second transparent overlay sheet is provided next to the thickness compensation sheet.

The components include a microcontroller, a module lead frame, a finger sensor lead frame, an antenna, and a plurality of electrical wires.

The microcontroller is also called a processing module, such as a secure processing module. It is placed in the microcontroller opening.

The module lead frame is adapted for being milled or cut, and it is placed in the contact module lead frame opening. The module lead frame comprises a plurality of first contact pads for contacting a card contact module.

The lead frame refers to a metal structure for carrying an electrical signal from one part of the lead frame to another part of the lead frame. The card contact module is intended for contacting a card reader to exchanged information with the card reader.

Similarly, the finger sensor lead frame is adapted for being milled or cut, and it is provided in the sensor lead frame opening. , the sensor lead frame comprising a plurality of second contact pads for contacting a fingerprint sensor.

The antenna includes a coil of an electrical conductor being embedded in the antenna carrier sheet. The antenna is intended for receiving energy or signal from an external source and for transmitting the energy or signal to electrical components of the card.

The electrical wires are electrically connected to electric contact pads of the microcontroller, to the first contact pads, to the second contact pads, and to the electrical conductor of the antenna.

This inlay allows easy change of electrical connections between electrical components. In other words, a user can another finger sensor or contact module with different pin out with only a little effort to assign the electrical wires to different pins.

One or more electrical wire can overlap with another electrical wire. This overlap allows flexible arrangement of electrical wires.

An intermediate transparent PVC sheet can be provided next to the second transparent overlay sheet. In other words, the inlay can include one or more additional sheet or layer. The additional sheet enables the inlay to have different properties to meet different needs of use, such as additional layers for enhanced protection.

The application provides a method of producing an inlay.

The method includes a step of providing an antenna carrier sheet.

After this, the antenna carrier sheet is milled, cut, or punched to provide the antenna carrier sheet with several openings, namely a first opening, a second opening, and a third opening. The first opening is intended for receiving a part of the microcontroller, namely a printed circuit board of the microcontroller. In other words, the first opening is adapted for receiving the printed circuit board. Similarly, the second opening is intended for receiving a module lead frame while the third opening is intended for receiving a sensor lead frame.

An adhesive tape is then placed next to the antenna carrier sheet such that the antenna carrier sheet is attached to an adhesive layer of the adhesive tape.

The antenna carrier sheet is later placed on a supporting surface, wherein the adhesive tape is resting on the supporting surface. This is to allow easy placement of parts into the openings of the antenna carrier sheet.

The printed circuit board is afterward inserted into the first opening, wherein the printed circuit board is attached to the adhesive tape. Likewise, the module lead frame is inserted into the second opening such that the module lead frame is attached to the adhesive tape. The sensor lead frame is inserted into the third opening, wherein the sensor lead frame is attached to the adhesive tape. The adhesive tape then keeps the printed circuit board, the module lead frame, and the sensor lead frame from moving with respect to the adhesive tape.

An antenna comprising a coil of an electrical conductor is later embedded in the antenna carrier sheet. The embedding fixes the coil of the electrical conductor to the antenna carrier sheet. In a general sense, this step of embedding can be also be done before or after the above step of placing the adhesive tape next to the antenna carrier sheet.

A plurality of electrical wires is afterwards attached to electrical contact pads of the printed circuit board, to electrical contact pads of the module lead frame, to electrical contact pads of the sensor lead frame, and to the electrical conductor of the antenna.

A thickness compensation sheet is provided with an opening to receive a moulded part of the microcontroller. The printed circuit board is electrically attached to one or more semiconductor chips while the moulded part covers and protects the semiconductor chips.

The thickness compensation sheet is then placed next to the antenna carrier sheet such that the opening receives the moulded part of the microcontroller.

The adhesive tape is afterwards removed from the antenna carrier sheet.

A first transparent overlay sheet is afterwards provided next to the antenna carrier sheet. The first transparent overlay sheet touches the antenna carrier sheet.

A second transparent overlay sheet is also placed next to the thickness compensation sheet, wherein the second transparent overlay sheet touches the thickness compensation sheet. This step can be done before or after the step of removing the adhesive tape from the antenna carrier sheet.

After this, the first transparent overlay sheet, the antenna carrier sheet, the thickness compensation sheet, and the second transparent overlay sheet are then laminated, wherein these sheets are pressed against each other to form the complete or final inlay <NUM>.

The method can include a further step of providing an intermediate transparent PVC sheet next to the second transparent overlay sheet. The intermediate transparent PVC sheet then touches the second transparent overlay sheet.

The application provides a biometric card. The card includes an inlay.

The inlay comprises a first transparent overlay sheet, an antenna carrier sheet, a thickness compensation sheet, a second transparent overlay sheet, a microcontroller, first contact pads of a module lead frame, second contact pads of a sensor lead frame, an antenna, and a plurality of electrical wires.

In particular, the antenna carrier sheet is provided next to the first transparent overlay sheet and it comprises a microcontroller opening, a module lead frame opening, and a sensor lead frame opening.

The microcontroller is provided in the microcontroller opening.

The first contact pads of the module lead frame are provided in the module lead frame opening.

The second contact pads of the sensor lead frame are provided in the sensor lead frame opening.

The antenna includes a coil of electrical conductor being embedded in the antenna carrier sheet.

The electrical wires are electrically connected to contact pads of the microcontroller, to the first contact pads, to the second contact pads, and to the electrical conductor of the antenna.

The card also includes a first printed PVC sheet, a first transparent PVC sheet, a second printed PVC sheet, a second transparent PVC sheet, a fingerprint sensor, and a contact module.

In detail, the first printed PVC sheet is provided next to a first transparent overlay sheet of the inlay.

The first transparent PVC sheet is provided next to the first printed PVC sheet.

The second printed PVC sheet is provided next a second transparent overlay sheet of the inlay.

The second printed PVC sheet is provided next to the intermediate transparent PVC sheet.

The second transparent PVC sheet is provided next to the second printed PVC sheet. The first transparent PVC sheet, the first printed PVC sheet, and the first transparent overlay sheet comprise a contact module opening and a fingerprint sensor opening.

The contact module is provided in the contact module opening and it is electrically connected to the first contact pads.

The fingerprint sensor is provided in the fingerprint sensor opening and it is electrically connected to the second contact pads.

An intermediate transparent PVC sheet can be provided between the second transparent overlay sheet and the second printed PVC sheet.

One or more electrical wires can overlap with another electrical wire.

The card often includes a first electrically conductive substance for electrically connecting the contact module to the first contact pads.

Similarly, the card often includes a second electrically conductive substance for electrically connecting the fingerprint sensor to the second contact pads.

The application provides a method of producing a card.

The method includes a step of providing the above-mentioned inlay.

A first printed PVC sheet is then provided next to a first transparent overlay sheet of the inlay. After this, a first transparent PVC sheet is provided next to the first transparent PVC sheet.

A second printed PVC sheet is later provided next to a second transparent overlay sheet of the inlay. Following this, a second transparent PVC sheet is provided next to the second printed PVC sheet. In a general sense, the second printed PVC sheet can be provided before or after the step of providing the first printed PVC sheet.

A first major surface of the first transparent PVC sheet is afterwards milled or cut such that a module lead frame body of a module lead frame is electrically detached from module lead frame contact pads of the module lead frame. In other words, the module lead frame contact pads are electrically isolated from each other.

Similarly, the first major surface is milled or cut such that a sensor lead frame body of a sensor lead frame is electrically detached from sensor lead frame contact pads of the sensor lead frame. The sensor lead frame contact pads are electrically isolated from each other.

The first major surface is milled or cut for providing a first recess to receive a contact module.

Similarly, the first major surface is also milled or cut for providing a second recess to receive a fingerprint sensor.

In a general sense, the above-mentioned steps of milling can be done different orders or sequences. The step of detaching the module lead frame contact pads from each other can be done before or after the step of detaching the sensor lead frame contact pads from each other. The step of milling to provide the first recess can be done before or after the step of milling to provide the second recess. The step of milling to provide the first or second recess can be done before or after the step of detaching the module lead frame contact pads or detaching the sensor lead frame contact pads from each other.

The method often includes a step of inserting a contact module into the first recess, wherein the contact module is electrically connected to the module lead frame contact pads and a step of inserting a fingerprint sensor into the second recess, wherein the fingerprint sensor is electrically connected to the sensor lead frame contact pads.

A first electrically conductive substance is often provided to electrically connect the contact module to the module lead frame contact pads.

A second electrically conductive substance is often provided to electrically connect the fingerprint sensor to the sensor lead frame contact pads.

In the following description, details are provided to describe embodiments of the application. It shall be apparent to one skilled in the art, however, that the embodiments may be practised without such details.

Some parts of the embodiments have similar parts. The similar parts may have the same names or the similar part numbers with an alphabet symbol. The description of one similar part also applies by reference to another similar part, where appropriate, thereby reducing repetition of text without limiting the disclosure.

<FIG> shows a card <NUM> with fingerprint biometrics.

The card <NUM> includes an improved inlay <NUM>, a plurality of flat sheets, and a plurality of electronic modules.

The inlay <NUM> and the flat sheets have essentially the same rectangular shape. The inlay <NUM> and the flat sheets are arranged in a stack, wherein an outer edge of the inlay <NUM> is placed next to outer edges of the flat sheets. The inlay <NUM> is positioned between the flat sheets. The electronic modules are embedded in the flat sheets and in the inlay <NUM>.

Referring to the flat sheets, they include a first transparent polyvinyl chloride (PVC) sheet <NUM>, a first printed PVC sheet <NUM>, an intermediate transparent PVC sheet <NUM>, and a second printed PVC sheet <NUM>, and a second transparent PVC sheet <NUM>.

As seen in <FIG>, a first major surface 15S1 of the first transparent PVC sheet <NUM> acts as an external surface of the chip <NUM> that a user can touch. A second major surface 15S2 of the first transparent PVC sheet <NUM> is placed next to a first major surface 17S1 of the first printed PVC sheet <NUM>. The second major surface 15S1 is positioned opposite the first major surface 15S2.

A second major surface 17S2 of the first printed PVC sheet <NUM> is placed next to a first major surface of the inlay <NUM>. The second major surface 17S2 is positioned opposite the first major surface 17S1.

A second major surface of the inlay <NUM> is placed next to a first major surface 20S1 of the intermediate transparent PVC sheet <NUM>. The second major surface of the inlay <NUM> is positioned opposite the first major surface of the inlay <NUM>.

A second major surface 20S2 of the intermediate transparent PVC sheet <NUM> is placed next to a first major surface 23S1 of the second printed PVC sheet <NUM>. The second major surface 20S2 is positioned opposite the first major surface 20S1.

A second major surface 23S2 of the second printed PVC sheet <NUM> is placed next to a first major surface 25S1 of the second transparent PVC sheet <NUM>. The second major surface 23S2 is positioned opposite the first major surface 23S1.

A second major surface 25S2 of the second transparent PVC sheet <NUM> acts as an external surface of the chip <NUM> that a user can touch. The second major surface 25S2 is positioned opposite the first major surface 25S1.

Referring to the inlay <NUM>, it includes a first transparent overlay sheet <NUM>, an antenna carrier sheet <NUM>, a thickness compensation sheet <NUM>, a second transparent overlay sheet <NUM>. The antenna carrier sheet <NUM> is also called an antenna sheet.

A first major surface 27S1 of the first transparent overlay sheet <NUM> is placed next to the second major surface 17S2 of the first printed PVC sheet <NUM>.

A second major surface 27S2 of the first transparent overlay sheet <NUM> is placed next to a first major surface 29S1 of the antenna carrier sheet <NUM>. The second major surface 27S2 is positioned opposite the first major surface 27S1.

A second major surface 29S2 of the antenna carrier sheet <NUM> is placed next to a first major surface 32S1 of the thickness compensation sheet <NUM>. The second major surface 29S2 is positioned opposite the first major surface 29S1.

A second major surface 32S2 of the thickness compensation sheet <NUM> is placed next to a first major surface 35S1 of the second transparent overlay sheet <NUM>. The second major surface 32S2 is positioned opposite the first major surface 32S1.

A second major surface 35S2 of the second transparent overlay sheet <NUM> is placed next to the first major surface 20S1 of the intermediate transparent PVC sheet <NUM>. The second major surface 35S2 is position opposite the first major surface 35S1.

Referring to the electronic modules as seen in <FIG>, they include a secure processing module <NUM>, a contact module <NUM> with contact pads 43CP of a millable module lead frame, a fingerprint sensor <NUM> with lead frame contact pads 46CP of a millable sensor lead frame, and a plurality of module electrical wires W. The secure processing module <NUM> is also called a computing processor or a microcontroller. The module lead frame and the sensor lead frame are adapted for milled or cut. In other words, the material and design of the module lead frame and the sensor lead frame are selected such that the module lead frame and the sensor lead frame are suitable for being milled.

Regarding the secure processing module <NUM>, it includes a printed circuit board (PCB) 40PCB and a moulded part 40MP. One end of the moulded part 40MP is attached to a surface of the PCB 40PCB.

The PCB 40PCB includes an essentially rectangular sheet, one or more semiconductor chips, and several electrical contact pads.

The rectangular sheet of the PCB 40PCB comprises a composite material that is flame resistant. The composite material includes a woven fiberglass cloth with an epoxy resin binder.

The electrical contact pads are placed on outer parts or edges of a contact surface of the rectangular sheet.

The semiconductor chips are placed on an inner or central part of the above-mentioned contact surface of the rectangular sheet of the PCB 40PCB. The semiconductor chips are electrically connected to the electrical contact pads via a plurality of chip electrical wires.

The moulded part 40MP has a shape essentially of a rectangular block. The moulded part 40MP is attached to the contact surface of the rectangular sheet of the PCB 40PCB and it encapsulates and covers the semiconductor chips.

The rectangular sheet of the PCB 40PCB and the antenna carrier sheet <NUM> have about the same thickness. Similarly, the moulded part 40MP has a height that is about the same as the thickness of the compensation sheet <NUM>.

The rectangular sheet of the PCB 40PCB is inserted in an opening of the antenna carrier sheet <NUM> while the moulded part 40MP is inserted in an opening of the compensation sheet <NUM>. The insertion is done such that the contact surface of the rectangular sheet is aligned with the second major surface 29S2 of the antenna carrier sheet <NUM>.

Regarding the contact module <NUM>, it has a shape essentially of a rectangular block. The contact module <NUM> has a first surface and a second surface that is placed opposite the first surface. The first surface includes a plurality of external module contact pads. The second surface includes a plurality of inner module contact pads. The external module contact pads are adapted for contacting electrical terminals of a card reader (not shown here).

The contact module <NUM> is inserted in an opening of the first transparent PVC sheet <NUM>, an opening of the first printed PVC sheet <NUM>, and an opening of the first transparent overlay sheet <NUM>. The insertion is done such that the first surface of the contact module <NUM> is aligned essentially with the first major surface 15S1 of the first transparent PVC sheet <NUM> and that the second surface of the contact module <NUM> is aligned essentially with the first major surface 29S1 of the antenna carrier sheet <NUM>.

As seen in <FIG> and <FIG>, the module lead frame contact pads 43CP have a thickness that is about the same as the thickness of the antenna carrier sheet <NUM>. The module lead frame contact pads 43CP are inserted in an opening of the antenna carrier sheet <NUM>. The insertion is done such that first ends 43CP1 of the module lead frame contact pads 43CP lie in a plane of the first major surface 29S1 of the antenna carrier sheet <NUM>. These first ends 43CP1 of the module lead frame contact pads 43CP are also placed next to the above-mentioned corresponding inner module contact pads. The module lead frame contact pads 43CP are also electrically connected to the inner module contact pads via an electrically conductive substance, such as an Anisotropic Conductive Film (ACF) adhesive.

Second ends 43CP2 of the module lead frame contact pads 43CP lie in a plane of the second major surface 29S2 of the antenna carrier sheet <NUM>.

Regarding the fingerprint sensor <NUM>, it includes a first rectangular part 46P1 and a second rectangular part 46P2, which is attached to the first rectangular part 46P1, as seen in <FIG>.

The first rectangular part 46P1 has a first surface and a second surface that is placed opposite the first surface. The first surface includes a plurality of external sensor contact pads. The second surface includes a plurality of inner sensor contact pads. The external sensor contact pads are adapted for contacting a finger of a user (not shown here) to sense and obtain fingerprint information of the finger.

The first rectangular part 46P1 is inserted in an opening of the first transparent PVC sheet <NUM>, an opening of the first printed PVC sheet <NUM>, and an opening of the first transparent overlay sheet <NUM>. The insertion is done such that the first surface of the first rectangular part 46P1 is aligned essentially with the first major surface 15S1 of the first transparent PVC sheet <NUM> and that the second surface of the first rectangular part 46P1 is aligned essentially with the first major surface 29S1 of the antenna carrier sheet <NUM>.

As seen in <FIG> and <FIG>, the sensor lead frame contact pads 46CP have a thickness that is about the same as the thickness of the antenna carrier sheet <NUM>. The sensor lead frame contact pads 46CP are inserted in an opening of the antenna carrier sheet <NUM>.

The insertion is done such that first ends 46CP1 of the sensor lead frame contact pads 46CP lie in a plane of the first major surface 29S1 of the antenna carrier sheet <NUM>.

These first ends 46CP1 of the sensor lead frame contact pads 46CP are also placed next to the above-mentioned corresponding inner module contact pads. The sensor lead frame contact pads 46CP are also electrically connected to the inner sensor contact pads via an electrically conductive substance, such as an Anisotropic Conductive Film (ACF) adhesive.

Second ends 46CP2 of the sensor lead frame contact pads 46CP lie in a plane of the second major surface 29S2 of the antenna carrier sheet <NUM>.

Referring to <FIG>, one end of the second rectangular part 46P2 is attached to an inner part of the second surface of the first rectangular part 46P1.

The second rectangular part 46P2 is inserted in an opening of the antenna carrier sheet <NUM>, an opening of the thickness compensation sheet <NUM>, an opening of the second transparent overlay sheet <NUM>, and a recess of the intermediate transparent PVC sheet <NUM>. The insertion is done such that a first surface of the second rectangular part 46P2 is aligned essentially with the first major surface 29S1 of the antenna carrier sheet <NUM>.

Regarding the module electrical wires W, the module electrical wires W are placed in a plane of the second major surface 29S2 of the antenna carrier sheet <NUM>.

The module electrical wires W are electrically connected to the electrical contact pads of the PCB 40PCB of the secure processing module <NUM>, to the module lead frame contact pads 43CP, which are electrically connected to the corresponding inner module contact pads of the contact module <NUM>, and to the sensor lead frame contact pads 46CP, which are electrically connected to the corresponding inner sensor contact pads of the fingerprint sensor <NUM>.

In this embodiment, the first transparent PVC sheet <NUM> has a thickness of about <NUM> microns, the first printed PVC sheet <NUM> has a thickness of about <NUM> microns, and the first transparent overlay sheet <NUM> has a thickness of about <NUM> microns.

The antenna carrier sheet <NUM> has a thickness of about <NUM> microns, the thickness compensation sheet <NUM> has a thickness of about <NUM> microns, and the second transparent overlay sheet <NUM> has a thickness of about <NUM> microns,.

The intermediate transparent PVC sheet <NUM> has a thickness of about <NUM> microns, the second printed PVC sheet <NUM> has a thickness of about <NUM> microns, and the second transparent PVC sheet has a thickness of about <NUM> microns.

In a further embodiment shown in <FIG>, the intermediate transparent PVC sheet <NUM> is left away. In this further embodiment, the second transparent overlay sheet <NUM> has a thickness of about <NUM> microns.

In another implementation, the card has external dimensions that comply with the standard International Organization for Standardization (ISO)/ International Electrotechnical Commission (IEC) <NUM>.

The external module contact pads of the contact module <NUM> have dimensions that comply with the ISO/ IEC <NUM>.

Functionally, the external sensor contact pads of the fingerprint sensor <NUM> are intended for contacting a finger of a user for sensing and obtaining fingerprint information of the finger. The fingerprint sensor <NUM> later sends the fingerprint information to the secure processing module <NUM>.

The external module contact pads of the contact module <NUM> are intended for contacting electrical terminals of a card reader (not shown here). The external module contact pads allow exchange of data or information between the secure processing module <NUM> and the card reader.

The secure processing module <NUM> is used for storing a reference template data. The secure processing module <NUM> then compares the user fingerprint information with the reference template data. If the secure processing module <NUM> determines the user fingerprint information matches with the reference template data, then the secure processing module <NUM> transmits a corresponding match signal to the card reader.

A user can print words and pictures on the first printed PVC sheet <NUM>, wherein the first transparent PVC sheet <NUM> allows a reader to see these words and pictures, which are printed on the first printed PVC sheet <NUM>.

Similarly, a user can print words and pictures on the second printed PVC sheet <NUM>, wherein the second transparent PVC sheet <NUM> allows a reader to see these words and pictures, which are printed on the second printed PVC sheet <NUM>.

<FIG> shows a module lead frame 43LF. The module lead frame 43LF includes a module lead frame body 43LFB, six module lead frame fingers 43LFF, and six module lead frame contact pads 43CP. The module lead frame body 43LFB is connected to the module lead frame fingers 43LFF. The module lead frame fingers 43LFF are connected to the corresponding module lead frame contact pads 43CP.

<FIG> shows a sensor lead frame 46LF. The sensor lead frame 46LF includes a sensor lead frame body 46LFB, eight sensor lead frame fingers 46LFF, and eight sensor lead frame contact pads 46CP. The sensor lead frame body 46LFB is connected to the sensor lead frame fingers 46LFF. The sensor lead frame fingers 46LFF are connected to the corresponding sensor lead frame contact pads 46CP.

In a general sense, the inlay <NUM> can include <NUM> or more layers. As an example, the inlay <NUM> can have <NUM> layers, an intermediate transparent PVC sheet being provided next to the second transparent overlay sheet <NUM>.

Similarly, the card <NUM> can include <NUM> or more layers. In other words, the card can have <NUM> or <NUM> layers.

A method of producing the inlay <NUM> and the card <NUM> is described below.

The method includes a step of providing an antenna carrier sheet <NUM>, as one of plurality of antenna carrier sheets in a large material sheet.

After this, the antenna carrier sheet <NUM> is punched to provide a first opening O1 for receiving the printed circuit board 40PCB of the secure processing module <NUM>, a second opening O2 for receiving a module lead frame 43LF, and a third opening O3 for receiving a sensor lead frame 46LF. This is shown in <FIG>.

An intermediary self-adhesive tape <NUM> is then placed on the first major surface 29S1 of the antenna carrier sheet <NUM> such that the self-adhesive tape <NUM> covers the antenna carrier sheet <NUM>. The intermediary self-adhesive tape <NUM> and the antenna carrier sheet <NUM> are also placed such that a non-adhesive surface of the self-adhesive tape <NUM> is resting on a support surface S, while a self-adhesive surface of the self-adhesive tape <NUM> faces the first major surface 29S1. This is shown in <FIG>.

A secure processing module <NUM> is later picked and placed into the first opening O1, wherein the printed circuit board 40PCB of the secure processing module <NUM> contacts the self-adhesive tape <NUM> and is attached to the adhesive layer of the self-adhesive tape <NUM>. The adhesive layer acts to fix the printed circuit board 40PCB to the self-adhesive tape <NUM>. In other words, the self-adhesive tape <NUM> prevents the printed circuit board 40PCB from falling off. The insertion is also done such that the electrical contact pads of the printed circuit board 40PCB lie in the plane of the first major surface 29S1 of the antenna carrier sheet <NUM>, as illustrated in <FIG>.

Similarly, a module lead frame 43LF is inserted into the second opening O2, wherein the module lead frame 43LF contacts the self-adhesive tape <NUM> and is attached to the adhesive layer of the self-adhesive tape <NUM>. The adhesive layer acts to fix the module lead frame 43LF to the self-adhesive tape <NUM>. The insertion is also done such that an exposed surface of the module lead frame 43LF lie in the plane of the first major surface 29S1 of the antenna carrier sheet <NUM>, as illustrated in <FIG>.

A sensor lead frame 46LF is picked and is placed in the third opening O3. wherein the sensor lead frame 46LF contacts the self-adhesive tape <NUM> and is attached to the adhesive layer of the self-adhesive tape <NUM>. The adhesive layer acts to fix the sensor lead frame 46LF to the self-adhesive tape <NUM>. The insertion is done such that an exposed surface of the sensor lead frame 46LF lie in the plane of the first major surface 29S1 of the antenna carrier sheet <NUM>, as illustrated in <FIG>.

An antenna A comprises a coil of electrical conductor is also placed on and is embedded into the antenna carrier sheet <NUM>. In other words, the antenna A is firmly attached to the antenna carrier sheet <NUM>. A heated tool presses the antenna onto the antenna carrier sheet <NUM>, which includes a thermoplastic material. The antenna A is shown in <FIG>, which shows a view of a top of the cash <NUM> of <FIG> when the layers <NUM>, <NUM>, <NUM>, <NUM> are transparent.

Electrical wires W are afterward electrically connected to the electrical contact pads of the printed circuit board 40PCB of the secure processing module <NUM>, to the second ends 43CP2 of the module lead frame contact pads 43CP, and to the second ends 46CP2 of the sensor lead frame contact pads 46CP, as illustrated in <FIG>.

The attachment of the electrical wires W is done using thermal compression bonding.

In a different implementation, the attachment of the electrical wires W is done using ultrasonic bonding. The ultrasonic bonding refers to rubbing together two pieces of metal with high energy such that surface impurities on surfaces of these two metals are scrubbed away and that underlying atoms of the metals are brought into close contact for bonding. The energy for this mechanically rubbing of the two metals is provided by a tool that vibrates mechanically at an ultrasonic frequency.

The electrical wires W also electrically connects the electrical conductor of the antenna A to the electrical contact pads of the printed circuit board 40PCB of the secure processing module <NUM>.

The electrical wires W can overlap each other, as seen in <FIG>.

A thickness compensation sheet <NUM> is provided as one of a plurality of compensation sheets in a large material sheet MS. The large material sheet MS is illustrated in <FIG>. The thickness compensation sheet <NUM> is punched to provide an opening to receive the moulded part 40MP of the secure processing module <NUM>. The thickness compensation sheet <NUM> is later placed on the 29S2 of the antenna carrier sheet <NUM> such the thickness compensation sheet <NUM> covers the outer end of the antenna carrier sheet <NUM>. The placing is also done such the opening of the thickness compensation sheet <NUM> receives the moulded part 40MP, as illustrated in <FIG>.

The partial inlay <NUM> is then flipped or turned over, wherein the self-adhesive tape <NUM> is then removed and replaced by a first transparent overlay sheet <NUM> is provided as one of a plurality of transparent overlay sheets in a large material sheet.

The partial inlay <NUM> is later flipped over again, wherein the first transparent overlay sheet <NUM> is resting and touching the support surface S, as seen <FIG>.

A second transparent overlay sheet <NUM> is provided as one of a plurality of transparent overlay sheets in a large material sheet and it is placed on the thickness compensation sheet <NUM> such that the second transparent overlay sheet <NUM> covers the thickness compensation sheet <NUM>, as illustrated in <FIG>.

The first transparent overlay sheet <NUM>, the antenna carrier sheet <NUM>, the thickness compensation sheet <NUM>, and the second transparent overlay sheet <NUM> are then laminated, wherein these sheets are pressed against each other to form the complete inlay <NUM>. In short, the lamination bonds or attaches the respective sheets to each other, thereby collating or bonding a stack of large material sheets.

Different from a printed circuit board, the electrical wires W allows flexible electrical connections between the secure processing module <NUM> and the module lead frame contact pads 43CP and between the secure processing module <NUM> and the sensor lead frame contact pads 46CP. The electrical connections can be configured easily by simply setting software parameters for defining required connections between parts. A user can then easily adapt its production process to use a different part with a different contact pad configuration. This is different from the printed circuit board that provides fixed electrical connections between parts.

A method of producing a card using the inlay <NUM> is described below.

The method includes a step of resting the inlay <NUM> on the support surface S, wherein the second transparent overlay sheet <NUM> is touching the support surface S, as illustrated in <FIG>.

A first printed PVC sheet <NUM> as one of a plurality of printed PVC sheets in a large material sheet is then provided and it is placed on the first transparent overlay sheet <NUM> of the inlay <NUM>, such that the first printed PVC sheet <NUM> covers the first transparent overlay sheet <NUM>, as illustrated in <FIG>.

A first transparent PVC sheet <NUM> is then provided as one of a plurality of transparent PVC sheets in a large material sheet and it is then placed on the first printed PVC sheet <NUM> such that the first transparent PVC sheet <NUM> covers the first printed PVC sheet <NUM>, as illustrated in <FIG>.

The partial card <NUM> is then flipped over such that the first transparent PVC sheet <NUM> is resting on and touching the support surface S, as illustrated in <FIG>.

An intermediate transparent PVC sheet <NUM> is provided as one of a plurality of intermediate transparent PVC sheets in a large material sheet and it is afterward placed on the second transparent overlay sheet <NUM> of the inlay <NUM> such that the intermediate transparent PVC sheet <NUM> covers the second transparent overlay sheet <NUM>, as illustrated in <FIG>.

A second printed PVC sheet <NUM> is provided as one of a plurality of printed PVC sheets in a large material sheet and it is later placed on the intermediate transparent PVC sheet <NUM> such that the second printed PVC sheet <NUM> covers the intermediate transparent PVC sheet <NUM>, as illustrated in <FIG>.

In a further embodiment shown in <FIG>, the intermediate transparent PVC sheet <NUM> is left away.

A second transparent PVC sheet <NUM> is provided as one of a plurality of transparent PVC sheets in a large material sheet and it is afterward placed on the second printed PVC sheet <NUM> such that the second transparent PVC sheet <NUM> covers the second printed PVC sheet <NUM>, as illustrated in <FIG>.

After this, the second transparent PVC sheet <NUM> is placed on the support surface S, as illustrated in <FIG>.

A sharp rotating tool is then applied perpendicularly to the first major surface 15S1 to cut or mill into the first major surface 15S1. The milling is done deep enough such that the module lead frame body 43LFB is cut such that it is electrically detached from the module lead frame contact pads 43CP. The milling creates a recess R1 that extends from the first major surface 15S1 to the module lead frame body 43LFB.

This milling also creates a shallow hole in the thickness compensation sheet <NUM>. In other words, the recess R1 extends from the first major surface 15S1 into a part of the thickness compensation sheet <NUM>. The recess R1 is shown in <FIG>.

Similarly, the first major surface 15S1 is milled into the partial card <NUM> such that the sensor lead frame body 46LFB is cut such that it is electrically detached from the sensor lead frame contact pads 46CP. The milling creates a recess R2 that extends from the first major surface 15S1 to the sensor lead frame body 46LFB. This recess R2 is shown in <FIG>.

This milling also creates a hole or recess R5 that goes through the thickness compensation sheet <NUM> and into the second transparent overlay sheet <NUM>. The recess R5 extends from the thickness compensation sheet <NUM> and into the second transparent overlay sheet <NUM>. This recess R5 is large enough to receive the second rectangular part 46P2 of the fingerprint sensor <NUM>. The recess R5 is shown in <FIG>.

The first major surface 15S1 is then milled again to create a bigger recess R3 that extends from the first major surface 15S1 to the module lead frame contact pads 43CP. This recess R3 is large enough to receive the contact module <NUM>. The milling also exposes the module lead frame contact pads 43CP. The recess R3 is shown in <FIG>. Put differently, the milling eats into the module lead frame contact pads 43CP.

The first major surface 15S1 is then milled again to create a bigger recess R4 that extends the first major surface 15S1 to the sensor lead frame contact pads 46CP. This recess is large enough to receive the first rectangular part 46P1 of the fingerprint sensor <NUM>. The milling also exposes the sensor lead frame contact pads 46CP. The recess R4 is shown in <FIG>. The milling eats into the sensor lead frame contact pads 46CP.

In another embodiment not shown here, the milling steps can also be applied in a reversed order or other sequence. In other words, the milling step to electrically detach the module lead frame body 43LFB from the module lead frame contact pads 43CP can be done before or after the step of milling to create recess R3. Similarly, the milling step to electrically detach the sensor lead frame body 46LFB from the sensor lead frame contact pads 46CP can be done before or after the step of milling to create the recess R4.

An electrically conductive substance is later placed either on the inner module contact pads of the contact module <NUM> or on the exposed module lead frame contact pads 43CP.

The contact module <NUM> is later inserted in the respective recess such that the inner module contact pads of the contact module <NUM> are electrically connected to the module lead frame contact pads 43CP via the electrically conductive substance.

Similarly, an electrically conductive substance is later placed either on the inner sensor contact pads of the fingerprint sensor <NUM> or on the exposed sensor lead frame contact pads 46CP.

The fingerprint sensor <NUM> is then inserted in the respective recess such that the inner sensor contact pads of the fingerprint sensor <NUM> are electrically connected to the sensor lead frame contact pads 46CP via the electrically conductive substance to form the complete card <NUM>, as illustrated in <FIG>.

Claim 1:
An inlay (<NUM>) for a card (<NUM>), the inlay (<NUM>) comprising
a first transparent overlay sheet (<NUM>),
an antenna carrier sheet (<NUM>) being provided next to the first transparent overlay sheet (<NUM>), the antenna carrier sheet (<NUM>) comprising a microcontroller opening (O1), a contact module lead frame opening (O2), and a finger sensor lead frame opening (O3),
a thickness compensation sheet (<NUM>) being provided next to the antenna carrier sheet (<NUM>),
a second transparent overlay sheet (<NUM>) being provided next to the thickness compensation sheet (<NUM>),
a microcontroller (<NUM>) being provided in the microcontroller opening (O1),
a module lead frame (43LF) being adapted for being milled and being provided in the contact module lead frame opening (O2), the module lead frame (43LFB) comprising a plurality of first contact pads (43CP) for contacting a contact module (<NUM>),
a finger sensor lead frame (46LF) being adapted for being milled and being provided in the finger sensor lead frame opening (O3), the finger sensor lead frame (46LF) comprising a plurality of second contact pads (46CP) for contacting a fingerprint sensor (<NUM>),
an antenna (A) comprising a coil of a conductor being embedded in the antenna carrier sheet (<NUM>), and
a plurality of electrical wires (W) being connected to the microcontroller (<NUM>), to the first contact pads (43CP), to the second contact pads (46CP), and to the antenna (A).