Patent ID: 7225537

Claim:
A method for making a Memory Card or similar device comprising a top layer of synthetic paper or other suitable material, a bottom layer of synthetic paper or other suitable material, and a core layer in which electronic components reside, said method comprising: (1) constructing a bottom layer with precisely positioned openings for external electrical contacts; (2) placing at least one mound of low shrinkage glue on an inside surface of the bottom layer; (3) mounting an electronic component, having external electrical contacts, on the at least one mound of low shrinkage glue, thereby forming a bottom layer assembly, wherein the external electrical contacts are positioned in alignment with the openings in the bottom layer; (4) partially curing the at least one mound of low shrinkage glue, wherein the electronic component is secured in a stable position; (5) positioning the bottom layer assembly in a bottom mold; (6) positioning the top layer in a top mold; (7) closing the top mold to the bottom mold in a manner that creates a void space between the top layer and bottom layer; (8) injecting a thermosetting polymeric material into the void space at temperature and pressure conditions which are such that: (a) the electronic component is secured in position by the partially cured glue while the electronic component and partially cured glue are immersed in the thermosetting material, (b) gases and excess polymeric material are driven out of the void space, (c) the electronic component is encapsulated in the thermosetting polymeric material before the partially cured glue becomes completely cured, (d) the shrinking of the partially cured glue as it is fully cured brings the lower surface of the external electrical contacts flush with the bottom surface of the bottom layer, and (e) the thermosetting polymeric material bonds with both the top layer and the bottom layer to produce a unified precursor Memory Card body; (9) removing the unified precursor Memory Card body from the mold device; and (10) trimming the precursor Memory Card or similar device to a desired dimension to produce a Memory Card.