This invention relates to manufacturing portable electronic tokens and in particular, but not exclusively, it relates to the manufacture of small, portable, articles which include an electronic circuit encapsulated within a plastics material, such as an electronic token of the "smart card" type.

Injection moulding is often used as a method of manufacturing small plastic articles. In such methods, usually small granules of the plastics material are heated so as to melt the material and the resulting fluid is injected at high temperature and pressure, perhaps 300 C and 2,00 PSI into a mould of a desired shape. The material is then allowed to set in the mould as it cools .

Such a method is fine for the manufacture, of small, homogeneous, articles. However, articles such as those commonly known as "smart cards" which comprises a number of components such as electronic circuits, input/output inter ces, substrates and labels are less well suited to the process since, the high pressures and temneraturcs

involved tend to displace inserts and indeed can damage the functioning thereof. Smart cards are generally manufactured by a lamination process.

The present invention seeks to provide an improved moulding technique for such articles.

According to the present invention there is provided a method of manufacturing portable electronic tokens comprising one or more electronic components and data input/output means encapsulated, within a plastics body and high tensile modulus members disposed as skins on at least two opposing main faces of the body and having graphics thereon; which method comprises locating the high tensile members against the side of a mould, locating the components between the members, injecting a reaction injection mouldable plastics material into the mould such that it encapsulates the components but is prevented, by the members, from contacting the surface of the mould, allowing the mater al to harden, and, removing the token from the mould.

Preferably, the articles are electronic tokens of the "smart card" type and have credit card sized dimensions, typically 8.5 by 5.4 by 0.075 cm. They may

- 3 - be of the type which use contactless coupling by means of an inductive loop, encapsulated w thin the plastics or resin material. In one embodiment, the portions of the token are co-extruded. The mould may comprise two endless belts which are located to cooperate in use to form a continuously moving mould cavity.

In an alternative embodiment, the high tensile members are arranged in two continuous sheets and are transported through the moulds, carrying the components and plastics material; the individual tokens being subsequently separated after hardening.

Preferably, after the components and plastics material have been introduced between the members, the edges of the members are sealed to form a sealed structure within which the plastics material is allowed to harden. To protect the graphics on the labels or skins, the graphics may be printed or otherwise deposited on their inner surface, i.e. the surface contacting the plastics material. The provision of the skins serves both to strengthen a card, as the skin is of a sufficiently high tensile modulus as to make a card substan a ly 3 igid but flexible, typically of similar flexibility and rigidity tυ a standard Laminated credit

card, and also serves as a mould release agent since the plastics material, which may for example be an epoxy, has an adhesive nature and thus problems can arise if this contacts the mould and adheres to it.

Any plastics material or mixture may be used which has the capability of hardening under a reaction injection moulding (RIM) process.

An embodiment of the invention will now be described by way of example only with reference to the accompanying Figures in which;

Figure 1 shows schematically the cross section of an electronic token when manufactured by a method embodying the present invention, and;

Figures 2 and 3 show schematically manuf cturing processes.

Re erring to Figure 1 , the token or card incorporates one or more integrated circuits 1 and capacitors 2. Rigid inserts 3, which may be made of str ^{^} ong metal or a rigid moulded compound, surround the circuits and capacitors so as ^* lo provide strengthening

and to resist damage caused by flexing the card. The power and input/output requirements of such a card are achieved by means of inductive coils 4 mounted on a substrate 5 and disposed generally around the periphery of the card. Printed labels 6 are positioned on the face of the card. These labels are made of polyester, polycarbonate, polyimide or a material of a similar tensile modulus and, in addition to their function as labels, also have a strengthening effect due to a 'double-skinned' effect. Without the labels the cards might be flaccid and their functions would probably be impaired. The printing is preferably on the inner surface 6a of the label to protect it. The electronic components wi thin the card are inter-connected by means of for example copper layers 7. The remainder of the material of the card is made from a moulded plastics or resin material such as polyurethane 8 or epoxy.

The card is assembled by means of a moulding process known as reaction injection moulding (RIM) . This is a well known process which is often used in the manufacture of large plastics articles such as car bumpers, surfboards and the like. The difference from conventional injection moulding techniques is that two materials are vised which are combined immediately befoie

moulding. These are a resin and a hardener which, when combined together harden within a fixed time period which is dependent upon the constituents. With conventional injection moulding, heat and pressure are required to melt the resin and inject it into a mould, whereupon the. resin sets as it cools. RIM is characterised by the fact that since the resin and hardener mixture is a liquid at a low temperature then high pressure and temperatures are not required.

In a first embodiment of the present invention the components of the card, other than the molten plastics material are fixed in place within a mould such that the labels are adjacent the sides of the mould, printed surface inward, and the other components lie between the labels. The resin is then added at a low pressure and temperature. Since the resin is in a fluid state, typically having the consistency of for example milk or thin cream, then the resin flows throughout the mould, making good contact with all the components and eventually completely covering and encapsulating them. It then begins to set after the. fixed time period, perhaps two to ten minutes, although resins are available which can begin to set after a few seconds. After the resin hat; set then the complete token is

removed from the mould and the process can be repeated.

Since the resin is not allowed to contact the mould walls the labels act as a release from the mould cavity walls .

In order to speed up the production rate the preprinted labels and components can be fed into a die which is also supplied with RIM fluid resin from a nozzle. This is shown in Figure 2 (which is not to scale), in which the die consists of a plurality of cavities 10 formed by two recessed endless belts running back to back to form a continuously moving mould cavity, moving in the direction shown by the arrows . The labels 6 and components 1 are fed into each moving cavity and the resin fed in through a nozzle 9. The components, labels and fluid, in the required configuration are then coextruded from the die to form continuous strips of completed cards, which subsequently set and are then separated as desired.

Figure 3 shows an alternative process in wnich the labels 6 are arranged in two continuous sheets which are spooled through a static, mould 11. The resin and components are applied to the labels in the same

relative disposition as that of Figure 2 and are transported through th mould with the labels, setting and hardening as they move. Preferably, 2 pairs of opposing pinch rollers, 12 and 13 are brought together periodically to pinch together and seal the ends of each labe . The rollers are then withdrawn until the labels have moved, in the direction of the arrow, a sufficient distance for the next pair of labels to be adjacent the rollers, and so on.