METHOD AND SYSTEM FOR MANUFACTURE OF AN ELECTRONIC INTERFACE CARD AND A CARD MANUFACTURED USING SAME

REFERENCE TO RELATED APPLICATIONS

Reference is made to the following related applications, the disclosures of which are hereby incorporated by reference and priority of which is hereby claimed:

PCT/IL2007/001378, filed November 8, 2007 and entitled ELECTRONIC INTERFACE APPARATUS AND METHOD AND SYSTEM FOR MANUFACTURING SAME; and

Hong Kong Patent Application 07104374.1, filed April 24, 2007 and entitled INTERFACE CARD AND APPARATUS AND PROCESS FOR THE FORMATION THEREOF.

FIELD OF THE INVENTION

The present invention relates to electronic interface cards, also known as

"smart cards" generally and more particularly to electronic interface cards having contact and/or contact-less functionalities.

BACKGROUND OF THE INVENTION

The following U.S. Patents are believed to represent the current state of the art:

7,278,580; 7,271,039; 7,269,021; 7,243,840; 7,240,847, 7,204,427 and 6,881,605.

SUMMARY OF THE INVENTION

The present invention seeks to provide improved electronic interface cards and methods for manufacturing thereof.

There is thus provided in accordance with a preferred embodiment of the present invention, a method for manufacture of an electronic interface card including forming at least one antenna coil on a first substrate, the antenna coil having loose end portions; placing a second substrate onto the first substrate over the antenna coil, the second substrate having an aperture through which at least parts of the loose end portions of the at least one antenna coil are exposed, extracting at least parts of the loose end portions through the aperture such that free ends of the loose end portions are positioned at a location remote from the substrate, forming an electrical connection between a chip module and the loose end portions at the location remote from the substrate and thereafter mounting the chip module onto the first substrate.

Preferably, the electronic interface card is formed by cutting at least the first and second substrates into individual cards and wherein the steps of forming an antenna coil and placing a second substrate are carried out prior to the cutting. Additionally, the method also includes laminating artwork layers and overlays onto the first and second substrates prior to the cutting step.

In a preferred embodiment of the present invention the method also includes bonding the free ends of the loose end portions to an extractable assembly prior to the cutting step. Additionally, the bonding includes attaching the free ends of the loose end portions to at least one plastic layer located in the aperture and forming part of the extractable assembly. Additionally, the method also includes disposing a release layer between the at least one plastic layer and the first substrate prior to the cutting step.

Preferably, the extracting includes milling of the artwork layers and overlays and of a periphery of the extractable assembly, followed by removal of the extractable assembly from the aperture, the removal being operative to pull with the

extractable assembly, the free ends of the loose end portions. Additionally, following the extracting, the loose end portions are cut and the extractable assembly is discarded.

In accordance with a preferred embodiment of the present invention following the extracting, the first substrate is milled at a location underlying the aperture to define a recess. Additionally or alternatively, the milling of the artwork layers and overlays defines an extension of the aperture and the chip module is located in the aperture and in the extension of the aperture. Alternatively, the milling of the artwork layers and overlays defines an extension of the aperture and the chip module is located in the aperture, in the extension of the aperture and in the recess. Preferably, the first and second substrates are laminated together over the antenna coil prior to the extracting. Additionally or alternatively, the first and second substrates are laminated together over the antenna coil prior to cutting. In accordance with a preferred embodiment of the present invention the first and second substrates are laminated together over the antenna coil and thereafter the artwork layers and overlays laminated thereto prior to the extracting.

There is also provided in accordance with another preferred embodiment of the present invention a method for manufacture of an electronic interface card including providing an electronic interface card precursor having a plurality of antenna coils on at least one substrate, the antenna coils, each having end portions, cutting the electronic interface card precursor into individual cards, forming an electrical connection between a chip module and the end portions at the location remote from the card and thereafter mounting the chip module onto the card by using an ultrasonic head. Preferably, the ultrasonic head is operative for adhering the chip module into the card. There is further provided in accordance with yet another preferred embodiment of the present invention a method for manufacture of an electronic interface card precursor including forming at least one antenna coil on a first substrate, the antenna coil having loose end portions and placing a second substrate onto the first substrate over the antenna coil, the second substrate having an aperture through which at least parts of the loose end portions of the at least one antenna coil are exposed.

Preferably, the method also includes bonding the free ends of the loose end portions to an extractable assembly. Additionally, the bonding includes attaching

the free ends of the loose end portions to at least one plastic layer located in the aperture and forming part of the extractable assembly.

In accordance with a preferred embodiment of the present invention the method also includes disposing a release layer between the at least one plastic layer and the first substrate. Additionally or alternatively, the method also includes laminating the first and second substrates over the antenna coil.

There is even further provided in accordance with still another preferred embodiment of the present invention a method for manufacture of an electronic interface card including providing an electronic interface card precursor having a plurality of antenna coils on a first substrate, the antenna coils, each having loose end portions, and a second substrate laminated onto the first substrate over the antenna coils, the second substrate having apertures through which at least parts of the loose end portions of the antenna coils are exposed, cutting the electronic interface card precursor into individual cards, extracting at least parts of the loose end portions of each card through the apertures such that free ends of the loose end portions are positioned at a location remote from the substrates, forming an electrical connection between a chip module and the loose end portions at the location remote from the card and thereafter mounting the chip module onto the card.

Preferably, the method also includes laminating artwork layers and overlays onto the first and second substrates prior to the cutting. Additionally, the extracting includes milling of the artwork layers and overlays and of a periphery of the extractable assembly, followed by removal of the extractable assembly from the aperture, the removal being operative to pull with the extractable assembly, the free ends of the loose end portions. In accordance with a preferred embodiment of the present invention following the extracting, the loose end portions are cut and the extractable assembly is discarded. Preferably, following the extracting, the first substrate is milled at a location underlying the aperture to define a recess.

Preferably, the milling of the artwork layers and overlays defines an extension of the aperture and the chip module is located in the aperture and in the extension of the aperture. Alternatively, the milling of the artwork layers and overlays

defines an extension of the aperture and the chip module is located in the aperture, in the extension of the aperture and in the recess.

There is also provided in accordance with yet another preferred embodiment of the present invention a system for manufacturing an electronic interface card, the system including an extractor, extracting at least parts of loose end portions of an antenna coil, at least partially embedded in a first card substrate, which loose end portions are exposed through an aperture formed in a second card substrate, laminated onto the at least first card substrate, the extracting being performed through the aperture such that free ends of the loose end portions are positioned at a location remote from the first and second card substrates, an electrical connection former, forming an electric connection between a chip module and ends of the loose end portions at the location remote from the first and second card substrates and a chip module mounter, thereafter mounting the chip module onto at least the first and second card substrates.

Preferably, the system also includes a card cutter, upstream of the extractor, and being operative for cutting at least the first and second card substrates into individual cards. Additionally, the system also includes a laminator, laminating artwork layers and overlays onto the first and second substrates upstream of the card cutter.

In accordance with a preferred embodiment of the present invention the system also includes a bonder, bonding the loose end portions to an extractable assembly upstream of the card cutter. Additionally, the bonder is operative for attaching the loose end portions to at least one plastic layer located in the aperture and forming part of the extractable assembly.

Preferably, the system also includes a release layer placer, disposing a release layer between the extractable assembly and the first substrate.

In accordance with a preferred embodiment of the present invention the extractor includes milling functionality for milling of the artwork layers and overlays and of a periphery of the extractable assembly and pulling functionality operative for removal of the extractable assembly from the aperture, pulling with it the free ends of the loose end portions. Additionally, the system also includes a loose end portion cutter operative downstream of the extractor to cut the loose end portions.

Preferably, the system also includes a recess former, operative downstream of the extractor to mill the first substrate, at a location underlying the aperture, to define a recess. Additionally or alternatively, the milling functionality defines an extension of the aperture and the chip module mounter is operative to mount the chip module in the aperture and in the extension of the aperture. Additionally, the milling functionality defines an extension of the aperture and the chip module mounter is operative to mount the chip module in the aperture, in the extension of the aperture and in the recess.

There is still further provided in accordance with another preferred embodiment of the present invention a system for manufacture of an electronic interface card including an electrical connection former for providing an electrical connection between a chip module and card formed from an electronic interface card precursor having a plurality of antenna coils on at least one substrate, the antenna coils, each having end portions and an ultrasonic head operative for mounting the chip module onto the card.

Preferably, the ultrasonic head is operative for adhering the chip module into the card.

There is yet further provided in accordance with a further preferred embodiment of the present invention an electronic interface card including a planar card element including a plurality of substrate layers, and having a card element thickness, a wire antenna at least partially embedded in at least one of the plurality of substrate layers and having loose end portions, the loose end portions each having a length which exceeds the card element thickness and a chip module electrically connected to ends of the loose end portions and mounted in a recess formed in at least one of the plurality of substrate layers, and wherein the loose end portions are folded.

Preferably, the card is manufactured using a method as described herein.

In accordance with a preferred embodiment of the present invention the card is manufactured using a system as described herein.

There is still further provided in accordance with another preferred embodiment of the present invention an electronic interface card inlay including a plurality of antenna coils on a first substrate, the antenna coils each having loose end portions, and a second substrate laminated onto the first substrate over the antenna coils,

the second substrate having apertures through which at least parts of the loose end portions of the antenna coils are exposed.

Preferably, the electronic interface card inlay also includes an extractable assembly disposed at least partially in at least some of the apertures, bonded to the loose end portions.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

Figs. IA and IB are respective simplified pictorial and sectional illustrations of an initial stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 2A and 2B are respective simplified pictorial and sectional illustrations of a second stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention; Figs. 3 A and 3B are respective simplified pictorial and sectional illustrations of a third stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 4A and 4B are respective simplified pictorial and sectional illustrations of a fourth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 5A and 5B are respective simplified pictorial and sectional illustrations of a fifth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 6 A and 6B are respective simplified side view sectional and partial top view illustrations of a sixth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 7A and 7B are respective simplified side view sectional and partial top view illustrations of a seventh stage in the manufacture of an electronic interface

card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 8A and 8B are respective simplified side view sectional and partial top view illustrations of a eighth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 9A and 9B are respective simplified side view sectional and partial top view illustrations of a ninth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 1OA and 1OB are respective simplified side view sectional and partial top view illustrations of a tenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention; Figs. HA and HB are respective simplified side view sectional and partial top view illustrations of a eleventh stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 12A and 12B are respective simplified side view sectional and partial top view illustrations of a twelfth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 13A and 13B are respective simplified side view sectional and partial top view illustrations of a thirteenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 14A and 14B are respective simplified side view sectional and partial top view illustrations of a fourteenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 15A and 15B are respective simplified side view sectional and partial top view illustrations of a fifteenth stage in the manufacture of an electronic

interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 16A and 16B are respective simplified side view sectional and partial top view illustrations of a sixteenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention;

Figs. 17A and 17B are respective simplified side view sectional and partial top view illustrations of a seventeenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention; and

Figs. 18A and 18B are respective simplified side view sectional and partial top view illustrations of a eighteenth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Reference is now made to Figs. IA and IB, which are respective simplified pictorial and sectional illustrations of an initial stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. As seen in Figs. IA & IB antenna coils 100 for a plurality of electronic interface cards are formed by wire embedding on a first inlay layer 102. Preferably the wire antenna is formed of wire having a diameter of approximately 130 microns and the first inlay layer is a sheet of PVC, preferably having a thickness of approximately 200 microns. First inlay layer 102 may be formed of PVC or of any other suitable material, such as Teslin®, PET-G (PolyEthyleneTerephthalate-Glycol), PET-F (PolyEthyleneTerephthalate-Film), polycarbonate or ABS. Wire embedding of antenna coils 100 may be carried out by known embedding techniques, typically employing an ultrasonic head commercially available from PCK Technology, Inc. of Islip, New York, U.S.A. End portions 104 of antenna coils 100 preferably are not embedded into first inlay layer 102. These "loose" end portions 104 are each typically of length of at least 800 microns. Reference is now made to Figs. 2 A and 2B, which are respective simplified pictorial and sectional illustrations of a second stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. As seen in Figs. 2A and 2B, a second inlay layer 106, preferably is a sheet of PVC of thickness approximately 200 microns, having formed thereon an array of apertures 108 is placed over first inlay layer 102 and over antenna coils 100. Second inlay layer 106 may be formed of PVC or of any other suitable material, such as Teslin®, PET-G (PolyEthyleneTerephthalate-Glycol), PET-F (PolyEthyleneTerephthalate-Film), polycarbonate or ABS. The arrangement of apertures 108 is such that the loose end portions 104 are exposed via apertures 108 in second inlay layer 106. Part of the length of each of the loose end portions 104 are preferably pulled so that they extend through apertures 108,

generally transversely to the planes of first and second inlay layers 102 and 106, while the remainder of the length remains folded adjacent first inlay layer 102, preferably adjacent edges of the aperture 108.

Reference is now made to Figs. 3A and 3B, which are respective simplified pictorial and sectional illustrations of a third stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. Here it is seen that preferably a layer of release material paper 110, typically having a thickness of about 70 microns, is placed in each aperture 108 over part of each of loose end portions 104 extending therethrough. It is appreciated that release material paper 110 may alternatively be obviated. The release layer 110 is preferably arranged such that the remainder of each of the loose end portions 104 lies alongside edges of the release paper or thereunder or extends transversely to the planes of the first and second inlay layers 102 and 106 alongside edges of the aperture 108. Reference is now made to Figs. 4 A and 4B, which are respective simplified pictorial and sectional illustrations of a fourth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. Here it is seen that a first layer of plastic 112, preferably PET (PolyEthyleneTerephthalate), typically having a thickness of about 70 microns and generally the same dimensions as release layer 110, is placed in each aperture 108 over release layer 110 and respective free ends 114 of loose end portions 104 of the antenna coil 100 are folded thereover, as shown. PET is preferred because it does not readily bond to PVC under lamination.

Reference is now made to Figs. 5 A and 5B, which are respective simplified pictorial and sectional illustrations of a fifth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. Here it is seen that a second layer of plastic 116, preferably PET (PolyEthyleneTerephthalate), typically having a thickness of about 70 microns and dimensions slightly larger than those of release layer 110 and first plastic layer 112 and nearly equal to those of aperture 108, is placed in each aperture 108 over first plastic layer 112 and over free ends 114 of the antenna coil 100 which are folded over first plastic layer 112.

As seem in Figs. 6A & 6B, the assembled array of inlays described hereinabove is then preferably laminated, causing antenna coils 100 to be partially embedded into second inlay layer 106 and embedding the free ends 114 of the loose end portions 114 of the antenna coils 100 in respective first and second layers of plastic 112 and 116. It is appreciated that release layer 110 allows the first layer of plastic 112 to be separated from the first inlay layer 102.

Reference is now made to Figs. 7 A and 7B, which are respective simplified side view sectional and partial top view illustrations of a sixth stage in the manufacture of an electronic interface card having both contact and contact-less functionalities, in accordance with a preferred embodiment of the present invention. The stage illustrated in Figs. 7A and 7B preferably follows the provision of the following additional layers which are preferably laminated onto the previously laminated assembly described hereinabove with reference to Figs. 6 A & 6B.

The additional layers include first and second artwork layers 120 and 122, preferably having respective thicknesses of approximately 100 and 200 microns, disposed alongside respective inlay layers 102 and 106; and first and second overlays 130 and 132 preferably having respective thicknesses of approximately 50 and 100 microns, disposed alongside respective artwork layers 120 and 122. Artwork layers 120 and 122 may be formed of PVC or of any other suitable material, such as Teslin®, PET- G (PolyEthyleneTerephthalate-Glycol), PET-F (PolyEthyleneTerephthalate-Film), polycarbonate or ABS. Overlays 130 and 132 may be formed of PVC or of any other suitable material, such as Teslin®, PET-G (PolyEthyleneTerephthalate-Glycol), PET-F (PolyEthyleneTerephthalate-Film), polycarbonate or ABS.

Following lamination of the above layers to form an integrated multi- layer card assembly, having a combined thickness of approximately 800 microns, individual multilayer cards are separated from each other in a conventional manner

Fig. 7A shows an individual card 140 about to be milled by a machine tool 142. The milling pattern is shown in Fig. 7B in dashed lines at reference numeral 144. Figs. 8A and 8B illustrate card 140 following milling by machine tool 142 of the circumferential periphery 145 of second plastic layer 116 and removal of portions of layers 122 and 132 lying thereabove and circumscribed thereby, thereby defining an aperture 146 extending through layers 106, 122 and 132.

Figs. 9A and 9B illustrate extraction of plastic layers 116 & 112 together with free ends 114 of loose end portions 114 of the antenna coil 100 and with release layer 110 by a lifting device 148, preferably including a suction device. It is recalled that the provision of release layer 110 enables this extraction to be readily carried out. This extraction extends, straightens and slightly tensions loose end portions 104, as shown. Alternatively, the release layer 110 may remain in aperture 146.

Figs. 1OA and 1OB illustrate cutting of loose end portions 104 just below release layer 110, preferably while loose end portions 104 are straightened and under tension. It is appreciated that if release layer 110 remains in aperture 146, the loose end portions 104 are cut just below plastic layer 112.

Figs. HA and HB illustrate the card 140 after cutting off and removal of layers 110, 112 and 116 and portions of loose end portions 104 and prior to milling of a recess in first inlay layer 102 underlying aperture 146, by a milling tool 142. Figs. 12A and 12B show the card, now designated by reference numeral 150, following formation of the milled recess, which is designated by reference numeral 152, preferably having a depth of approximately 80 microns.

Reference is now made to Figs. 13A and 13B, which illustrate a chip module 160, such as a smart card chip or any other suitable semiconductor device, having a peripheral portion of a bottom surface thereof coated with a layer of hot-melt adhesive 162, about to be associated with card 150. Adhesive 162 may or may not be a hot-melt adhesive, and may be, for example, a pressure activatable or an ultrasonic energy activatable adhesive. As a further alternative, adhesive 162 may be obviated.

Figs. 14A and 14B illustrate soldering, laser bonding or any other suitable type of bonding of ends 164 of loose end portions 104 to respective pads 166 on the bottom surface of chip module 160, which is preferably arranged in an orientation at right angles to the plane of the card 150.

Reference is now made to Figs. 15A and 15B, which illustrate chip module 160 rotated by 90 degrees relative to its orientation in Figs. 14A & 14B and ready to be inserted into aperture 146 while loose end portions 104 are being folded thereunder. Figs. 16A and 16B illustrate the chip module 160 located in aperture 146.

Figs. 17A and 17B illustrate the chip module 160 being bonded in engagement with

card 150 at aperture 146 and recess 152 by a heating element 170. Figs. 18A and 18B illustrate a further cold lamination step employing a non-heating pressure element 172.

According to an alternative embodiment of the invention, element 170 may be an ultrasonic head. According to a further alternative embodiment of the invention, where the adhesive is a pressure activated adhesive, the step of Figs. 17A &

17B may be obviated and the chip module is bonded to the card substrates by the step of

Figs. 18A & 18B.

It will be appreciated by persons skilled in the art that the scope of the present invention is not limited by what has been particularly shown and described hereinabove. Rather, the invention includes both combinations and subcombinations of the various features described hereinabove as well modifications and variations thereof which would occur to persons skilled in the art upon reading the foregoing description together with the drawings and which are not in the prior art.