JP2008541208A - Electronic card and manufacturing method thereof - Google Patents

Abstract

The electronic card 10 includes a digital processor, an electrochemical battery, and a communication port. The processor and battery are essentially coplanar, sandwiched between and covered by two flexible covers 12,14, preferably made of an insulating plastic material and preferably covered by them. Fit parts. Communication ports can include, for example, smart card contact pads, stripe emulators, RF ports, IR ports, and the like. The battery may include a rechargeable battery. In the preferred embodiment, at least the processor is carried by a flexible printed circuit (PC board). In another preferred embodiment, the switches and / or indicators are also carried by the PC board. A method for manufacturing an electronic card is also disclosed with at least two elements.
[Selection] Figure 8

Description

  The present invention relates generally to electronic security, and more particularly to secure electronic transaction cards such as smart cards.

  There are numerous applications for electronic security. For example, security is desired or required for providing financial transactions or access to various physical and non-physical resources. A field greatly related to electronic security is a financial transaction area such as a credit card or a debit card.

  Standard credit cards, debit cards and other financial transaction cards (hereinafter “transaction cards”) typically have a plastic body with an embossed 16 digit account number and other data. The magnetic stripe is usually referred to as a “stripe” and is fixed to the back of the card. The stripe typically magnetically encodes the account number and / or other data.

  A stripe is typically a magnetic tape material, much like the magnetic tape used in digital data recording. Stripe materials typically include magnetic oxides and binder compounds that provide magnetic stripes with the data encoding capabilities and physical durability properties required for transaction card applications. While these magnetic tape components are optimized for transaction card applications, the magnetic tape used for the magnetic stripe on the transaction card is much like a standard digital data recording tape.

  The two most common magnetic oxides used in magnetic stripe cards are referred to as low coercivity (LoCo) and high coercivity (HiCo) magnetic oxides. Coercivity measures how hard it is to magnetize or demagnetize a stripe and is measured in Oersteds. Low coercivity magnetic stripes are typically 300 oersteds and high coercivity magnetic stripes are over 2700 oersteds. High coercivity magnetic stripes require about three times the energy of low coercivity magnetic stripes for encoding and erasing. Many transaction card applications are moving towards HiCo magnetic stripes because it is more difficult to accidentally erase the encoded data than LoCo magnetic stripes. This further provides the durability and readability of the encoded data used for many applications.

  The magnetic stripe encoding in transaction cards has been re-optimized for transaction card applications, but typically follows standard digital recording techniques. The encoded data takes the form of zones of magnetization in a magnetic stripe with alternating magnetic poles. The north and south poles of the magnetized zone alternate in direction by providing an encoding technique that can represent binary “0” and “1” according to the binary digital code.

  The standard encoding technique for magnetic stripes in transaction cards is two magnetizations where binary 0 is represented by a long magnetization zone and binary 1 is half the length of a long magnetization zone of 0 each. F2F (Aiken Duplex / Frequency) code represented by a zone. The exact length of these magnetization zones is determined by how much data is to be recorded on the magnetic stripe. For example, in the International Organization for Standardization (ISO) standard 7811-2 / 6, track 2 data is encoded in a long zero zone of 75 bits per inch, or 75 per inch. This is equal to a length of 0.1333 inches for the zero magnetization zone. A binary 1 may be half that length, or 0.00666 inches long. Other lengths for different data densities are obtained, such as 210 bits per inch used in track 1 and track 2 of the magnetic stripe.

  Reading of the encoded data in the magnetic stripe is accomplished by the magnetic read head supplementing the magnetic flux region extending from the magnetized zone in the stripe. The read head converts the magnetic flux changing in the coil of the read head into a voltage pattern that mirrors the magnetization zone of the encoded data. The voltage pattern can then be converted by decoding electronics into binary 0s and 1s of data well known in the art.

  The magnetic stripe encoder consists of a magnetic write head and an electronic current drive circuit that can magnetize (saturate) all of the magnetic oxide in the stripe. By creating an alternating zone of magnetization direction in the stripe that would form the data encoding of the magnetic stripe, the symbolized current in the write head can alternate direction, and the magnetic stripe data Create an alternating zone of magnetization direction in the stripe that will form the encoding. Transaction cards typically comprise a card's own stripe that is encoded into an account and / or other information in a commercial magnetic stripe encoder before reaching the consumer.

  Processing of magnetic tape applications for transaction cards, encoding of magnetic stripes, and reading of data encoded in magnetic stripes in use are reliable and cost effective for transaction cards based on financial, ID and application. There was a way. However, the relative ease in reading, encoding, or re-encoding magnetic stripe data is counterfeited, copied to one or more cards (often referred to as “skimming”), and other unauthorized exploits. Produced a magnetic stripe transaction card that is easy to receive. Skimming fraud has grown independently around the world and has reached a financial dollar loss that requires immediate resolution.

  There are many security issues with standard transaction cards. For one thing, the stripe is static and unencrypted, and in a real sense the transaction card thief “steals” the data from the stripe, and for unauthorized transactions it Will be allowed to use. This is because the transaction data of a standard magnetic stripe card is “bare”, that is, not encrypted. Thus, a counterfeit transaction card can be freely used by a thief until the card is canceled.

  The problem of skimming and counterfeiting is being addressed by Magtec, which has a magnet printing technology. Magneprint (R) is a card security technology that can search for "skimmed" or magnetically tampered counterfeit cards. Magneprint (R) identifies magnetic stripe cards individually so that fingerprints can individually identify people. Magneprint (R) was discovered at Washington University, St. Louis, Missouri, USA. MagTech has refined this technology so that it can be put into practical use and has an exclusive license to this technology market. Magneprint technology requires a modified card reader for its implementation that would abandon millions of outdated card readers.

  In addition to the lack of security technology, standard transaction cards are also extremely limited in storage capacity. In other words, standard cards have a limited stripe for their memory. As such, standard cards are not electronic cards, such as cards that incorporate electronic components such as on-board processors and / or digital memory, and are subject to significant limitations in their functionality. It is.

  An example of an electronic card is called a “smart card”, which includes an on-board processor and digital memory. By supplying the on-board electronic components, the smart card can execute a security protocol such as encryption and can store a large amount of user information and the like.

  A common standard for smart cards is referred to as the ISO 7816 standard. In accordance with this protocol, a smart card is provided with an electronic interface that includes a number of conductive and externally accessible contact pads connected to an embedded secure processor. The smart card is inserted into a smart card reader that makes electrical contact with the contact pad to provide power and communication with the secure processor. The smart card can also include a standard stripe that does not exchange any information with the secure processor.

  Smart cards that use memory chips or microprocessor chips have been introduced to provide increased storage of data and to protect against several types of fraud found within magnetic stripe transaction cards. Smart cards reduce some types of fraud, but are more expensive than magnetic stripe transaction cards, and magnetic stripe readers when performing transactions are readers that can read data storage chips and magnetic stripes Had to be replaced. These cost factors and inertia in changing the existing infrastructure built around magnetic stripe transaction cards and applications (eg “legacy” card readers) Blocked general acceptance.

  Another factor related to the slow acceptance of smart cards in the United States is the lack of a visible benefit to end users or consumers. Consumers are content to use magnetic stripes just as they use a chip to complete a transaction.

  As mentioned above, smart cards have not been applied extensively in the United States while being widely applied overseas. A major reason for this is the investment made by millions of vendors of legacy card readers that cannot communicate with smart card secure processors. Also, smart cards according to the ISO 7816 standard suffer from their own limitations, including severely restricted I / O, the inability to provide “smart” transactions with legacy card readers, and so on.

  Another limitation of typical smart cards is the lack of interaction with the user when the smart card is not in contact with the smart card reader. This limitation is due to the fact that prior art smart cards do not have an onboard power supply. Therefore, the technical parts are in a dormant state and do not allow alternating current. This restriction prevents myriad characteristics such as account selection or security characteristics such as locking a card.

  Another proposed approach uses a general processor and stripe emulator that is not yet used, but works with legacy card readers. As used herein, the term “striped emulator” will refer to a transaction card in which the data transferred to the legacy card reader is under the control of the general processor. This approach will be referred to herein as an “emulator card” which is a form of electrical card.

  Emulator cards potentially have many obvious advantages over standard credit cards. As an example, a single card can emulate many different transaction cards and greatly reduce the bulk of a user's wallet. For example, an emulator card can emulate a VISA card, a master card, and an ATM card. In addition, since the emulator card includes a processor, an additional function such as a security function can be executed.

  However, emulator cards also have their own limitations. As an example, since a general processor is used, the security level of the card is lowered. For example, hackers can obtain data stored in potentially unsecured electronic memory. Also, emulator cards are designed to work with legacy card readers, so they do not handle smart card protocols. For example, as with a standard credit card, data flows from the emulator card to the legacy card reader and not vice versa. In addition, the information that can be supplied by the emulator card is limited by the amount of information that a standard stripe can hold and can be read by a legacy card reader.

  The need for fraud reduction with versatile and inexpensively manufactured electronic cards is urgent. In the United States, fraud tends to range from 7.5 to 12 basis points in credit card transactions, and skimming itself is estimated at a cost of $ 8 billion in 2005. Due to skimming, it is 60%, and along with the tendency of fraud of basic points from 25 to 40, the need for it is even more urgent internationally. Nevertheless, merchants in the United States and elsewhere need to replace all of their current magnetic card transaction equipment for a variety of reasons, including cost, inconvenience, confusion, and lack of reliability. Reluctant to invest in.

  In addition to financial transactions, there are other uses for electronic cards. For example, electronic cards have been used for security purposes, for example, to allow personnel to a high security area of a building (“access control”). Electronic cards can therefore be used for a variety of purposes that require the carrier's certification and / or status to be proved by a physical card or “evidence”.

  As described above, electronic cards tend to be relatively expensive compared to standard, non-electronic magnetic stripe cards. This is partly due to the cost of electronic components and partly due to the complexity of electronic card manufacturing. For example, care must be taken during the lamination of the electronic card to prevent damage to electronic components sensitive to heat and / or pressure. Also, the electronic card should remain thin, flexible and the same desired size as a standard card. As another example, stripe emulators tend to be difficult to design and manufacture to work with legacy readers.

Furthermore, supplying power to the electronic circuitry of the electronic card tends to be a problem. For example, smart cards are powered from their readers, limiting their utility in contactless applications. A good solution for supplying power to ubiquitous electronic cards has not yet been found in the prior art.
These and other prior art limitations will become apparent to those skilled in the art upon reading the following description and studying several drawings.

  Many non-limiting examples of electronic cards that address the problems discussed above and the limitations of conventional transaction cards and electronic cards are represented. As will be apparent to those skilled in the art, the methods and apparatus disclosed herein are applicable to a wide variety of problems that are required or improved with improved electronic cards.

  An object of the present invention is to provide an electronic card with a thin and flexible substrate power supply.

  Another object of the present invention is to provide an efficient and cost effective method of manufacturing an electronic card.

  Another object of the present invention is to provide an improved smart card with improved I / O capacity.

  Another object of the present invention is to provide an electronic transaction card with improved security.

  Another object of the present invention is to provide an improved emulator transaction card.

  In some embodiments, described as an example rather than a limitation, the electronic card is a thin, flat digital processor, a thin, flat electrochemical battery, a communication port, a first flexible cover, and a second flexible card. Cover included. The digital processor desirably has a first substantially planar surface and a substantially opposite substantially planar second surface, the first surface, the second surface, and At least one of the cross sections of the processor defines a maximum surface area and is disposed substantially coplanar with the processor and has a battery that provides power to the processor. The communication port is connected to the processor. Each of the second flexible cover opposite the first flexible cover has a surface area that is larger than the maximum surface area of the digital processor and battery. The processor and battery are sandwiched between and surrounded by the first flexible cover and the second flexible cover.

  In the preferred embodiment, the electronic card includes a flexible circuit board. In another preferred embodiment, at least one of the first cover and the second cover is contoured to fit over the circuit board, processor and battery. In another preferred embodiment, one or more switches are connected to the circuit board. In another preferred embodiment, one or more indicators are connected to the circuit board. In another preferred embodiment, the processor is connected to the circuit board in a flip chip manner. In another preferred embodiment, the processor is connected to a circuit board with bonded wires. In another preferred embodiment, the bonded wire has a low loop height. In another preferred embodiment, the processor is encapsulated with respect to the printed circuit board. In another preferred embodiment, the battery includes two or more batteries. In another preferred embodiment, the battery is not rechargeable. In another preferred embodiment, the battery is rechargeable. In another preferred embodiment, the battery includes a rechargeable battery and a non-rechargeable battery. In another preferred embodiment, the battery is part of a power supply that includes a power filter.

  In some embodiments, which will be described by way of example and not limitation, an electronic card manufacturing method includes making a flexible printed circuit board, attaching at least one processor to the printed circuit board, and printing at least one battery. Connecting to a circuit board, encapsulating at least one processor, creating a top cover and a bottom cover, and sandwiching a printed circuit board, processor and battery between the top cover and the bottom cover.

  In one embodiment, which will be described by way of example rather than limitation, the improved smart card is located at least partially in the card body with an externally accessible card interface including a signal port, a power port, and a ground port. A secure processor connected to the signal port, power port, and ground port, and a general processor located at least partially within the card body, and connected to a power source located at least partially within the card body Connected to at least one of the secure processor and the general processor, the general processor operating to power and communicate with the secure processor when the secure processor is used in an improved smart card mode Non-contact Including the port.

  In some embodiments, as described by way of example rather than limitation, a secure transaction card includes a card body, a secure processor at least partially disposed within the card body, and a general processor at least partially disposed within the card body. A power source disposed at least partially within the card body, and a contactless communication port connected to at least one of the secure processor and the general processor.

  In one embodiment, which is described by way of example rather than limitation, a swipe emulating broadcaster system includes an elongated core material, a winding having multiple turns around the core material, and a card reader readhead. And a signal generator having a broadcast driver signal and connected to the coil so that the coil can provide a dynamic magnetic field that emulates the insertion of a magnetic stripe transaction.

  In the preferred embodiment, the signal generator includes a processor having a digital output and a signal processing circuit that converts the digital output into a broadcaster driver signal. In another preferred embodiment, the signal generator is a digital signal generator. In another preferred embodiment, the coil is one of a plurality of coils. In another preferred embodiment, at least one of the plurality of coils is a track coil. In another preferred embodiment, at least one of the plurality of coils is a cancellation coil. In another preferred embodiment, the coil includes a coil wound around a core. In another preferred embodiment, the coil includes a wire formed around the core by a process that includes at least deposition of a conductive material and etching of the conductive material.

  In some embodiments, described as an example rather than a limitation, a method of creating a low loop adhesion for thin contouring applications has a first surface of the assembled semiconductor with a plurality of circuit board contact pads. Attaching to a first surface of a circuit board such that a second surface of the die opposite the first surface is exposed to provide access to a plurality of die contact pads; Wire bonding the first end of the wire to a circuit board contact pad and wire bonding the second end of the wire to a die contact pad so that the loop height of the wire is the first of the die. On the surface of 2 to be the same as 5 mil and on the first surface of the circuit board to be the same as 20 mil.

  These and other examples, aspects, and advantages will become apparent to those of ordinary skill in the art upon reading the following description and studying the various figures.

  As already mentioned, there are a great many applications for electronic security. One of many applications is to provide security for financial transactions, i.e., financial transactions that use transaction cards such as credit cards and debit cards. In the following preferred embodiment, an important point will be placed on transaction card security with the understanding that other uses for improved electronic security are within the essence and scope of the present invention.

  Several preferred embodiments will now be described with reference to the drawings, in which like parts are given like reference numerals. The preferred embodiments are intended to be illustrative rather than limiting.

  FIG. 1 is an example of an electronic card 10 that includes a card body 11 that is described by way of example and not limitation. The card body is made of a thermoplastic material such as polyvinyl chloride (PVC) in the preferred embodiment, but other materials with sufficient flexibility and durability are also suitable. For example, other thermoplastics can be used as well as thin metals (eg, stainless steel). Of course, if a conductive material is used for the card body 11, proper electrical insulation from electrical and / or electronic components must be maintained. In addition, other materials such as resins, carbon fibers, organic and non-organic materials, etc. are also suitable as various alternative examples. In summary, the card body 11 can be made of a suitable material that is strong enough and durable enough to be used in a transaction card.

  The preferred electronic card 10 has a front surface 12 that is provided with an electronic interface 16. This is a non-limiting example of a communication port for the electronic card 10. In other embodiments, the interface 16 may be omitted or an additional communication port may be provided.

  The illustrated interface 16 includes, in this example, a number of contact pads formed in a form in accordance with the International Organization for Standardization “smart card” standard ISO7816. In this preferred embodiment, the electronic card can be used as a legacy mode smart card. On the front surface 12, an institution identifier 18, an institution number 20, an account number, and a client name 24 are shown. The account number is preferably embossed on the electronic card 10 to provide a raised number for the credit card imprinting machine.

  FIG. 2 shows the back surface 14 of the preferred electronic card 10. In this preferred embodiment, a magnetic stripe emulator 26 is provided on the back surface 14 that can communicate with a prior art legacy magnetic stripe reader. The stripe emulator 26 is therefore another non-limiting example of a communication port.

  The electronic card also has, for example, an on / off button 28, an “on” indicator 30, and an “off” indicator 32. In this preferred embodiment, the “on” indicator 30 may be a green LED and the “off” indicator 32 may be a red LED. Also seen on the back 14 of the desired card is an account interface 34. Each account interface 34 preferably includes an account indicator LED 36 and an account selector switch 38. Each account interface 34 may also have, for example, printed information certifying the account and expiration date. The back surface 14 also has instructions 40, an institution identifier 41, a signature box 42, and various other optional printed information in this example.

  FIG. 3 is a block diagram relating to a desirable circuit configuration of the electronic card 10 and is represented as a non-limiting example. In this example, the electronic card 10 includes a secure processor 44, a general processor 52, and a magnetic stripe emulator 64. In this embodiment, both secure processor 44 and general processor 52 are coupled to interface 16 via ISO 7816 bus 48.

  The secure processor 44 is preferably a commercially available smart card chip having various tamper-resistant characteristics such as secure cryptographic functions and tamper-resistant storage 46. An example of the secure processor 44 is a P8WE6032 processor, given by way of non-limiting example, manufactured by Philips, Germany. Similar devices are manufactured by Hitachi, Infineon, Toshiba, ST and others. As described above, the secure processor 44 in this example is electrically connected to the interface 16 via the bus 46.

  General processor 52 is also connected to bus 48 in this example, and is therefore connected to both secure processor 44 and interface 16. In addition, in this example, the general processor 52 is connected to the secure processor 44 by the I / O 2 line 50. In this embodiment, the memory 54 is connected to the general processor 52 by an I / O 2 line 50. General processor 52 is also connected to power source 56, display 58, switch 60, and other I / O 62 in this example.

  In another example, general processor 52 communicates with secure processor 44 over bus 48 in a mode according to ISO 7816. In such an embodiment, no connection to any other secure processor is required (eg, the I / O2 line 50 connection may be omitted).

  The power source 56 is preferably an electrochemical battery disposed within the card body 11. It can be either a non-rechargeable battery or a rechargeable battery. If the power source 56 is a non-rechargeable battery, it should have sufficient capacity to supply power to the electronic card 10 for its useful life. If the power source 56 is rechargeable, the electronic card 10 can be used indefinitely. Rechargeable batteries include, for example, magnetic induction (e.g., through induction coils or broadcaster coils), photovoltaic cells built into the body 11, piezoelectric materials built into the electronic card 10, another electronic connector, dynamic recharging. It can be recharged through interface 16 by structure (eg, magnets and coils), or other suitable structure. For example, in some cases, rectification of ambient RF energy may provide sufficient power to power the electronic card 10, charge the battery, or store additional charge, for example, in a capacitor.

  Another preferred embodiment includes first and second batteries disposed within the card body. For example, a non-rechargeable battery can serve as a first battery, a rechargeable battery can serve as a second battery, and vice versa. These preferred embodiments are given as non-limiting examples.

  Since the power source 56 is built into the electronic card 10, it must be thin. This is because the electronic card 10 must bend within a certain range for many applications. For example, an electronic card 10 used for transaction card applications is ISO 7816, which is 85.60 mm (~ 3370 mils) wide, 53.98 mm (~ 2125 mils) high and 0.76 mm (~ 30 mils) thick. Must conform to the standard. This is often referred to as the “CR80” format, approximately 3½ “by2”, which fits well with a standard wallet. However, other formats may be used that are larger, smaller or differently configured than the CR80 format. As a non-limiting example, an electronic card smaller than the size of CR80 is made, for example, to fit a key holder.

  The card must be somewhat flexible so that it can be used, for example, in pluggable legacy card readers, and it is desirable that the power source be somewhat flexible if it is relatively large in the surface area. However, flexibility is not an issue if the batteries are relatively small within the surface area, or if several small batteries are coupled together to form the power source 56. Also, for example, if heat and / or pressure lamination techniques are used to manufacture the electronic card 10, it is important that the power source 56 can withstand the heat and / or pressure.

  Examples of suitable batteries are manufactured by Varta Microbattery of Ellwangen in Germany and Solicore of Lakeland in Florida. The battery is desirably electrochemical in nature, although other battery types or capacitive storage elements are used. Suitable electrochemical batteries may include, but are not limited to, lithium-polymer, Ni-MH, lithium, lithium ion, alkali, and the like.

  The general processor 52 may be, for example, a PIC16 or PIC18 microcontroller. In another embodiment, general processor 52 may include an ASIC chip. In further embodiments, the general processor may be any form of logic (eg, state machine, analog processor, etc.) that performs the desired function.

  The display 58 can be, for example, the previously disclosed LED device. As another non-limiting example, the display 58 can include a flexible LCD display. It is desirable that the LCD display be flexible when it has a relatively large surface area. Switch 60 may comprise any form of electrical switch or device with switch functionality for providing input or control to electronic card 10. The processor 52 may provide software that debounces the algorithm associated with such a switch, for example. Other I / O 62 may include many other I / O subsystems. These may include, but are not limited to, audio, tactile, RF, IR, optics, keyboard, biometric I / O or other I / O. The secure processor 44 may also provide RF or IR I / O according to the ISO 7816 standard.

  Also in this preferred embodiment, connected to the general processor 52 is a magnetic stripe emulator 64, which can be used in the electronic card 10 in a mode to emulate a prior art magnetic stripe card. In this non-limiting example, the magnetic stripe emulator 64 includes a buffering circuit 66 that converts the output from the general processor 52 into a waveform suitable for magnetic stripe emulation. In this preferred embodiment, buffering circuit 66 includes a conversion circuit typically implemented as an RC network. According to the broadcaster, the RC network forms an RCL network for adjusting the waveform. RC networks and their equivalents are well known to those skilled in the art.

  In this example, the magnetic stripe emulator 64 further includes a broadcaster 68. As used herein, the term “broadcaster” is used to “broadcast” a fluctuating magnetic signal that emulates the behavior (“insertion”) of a transaction card stripe past the read head of a magnetic card reader. Or refer to more induction coils.

  Broadcaster 68 may be electrically connected to buffering circuit 66, and preferably receives two signal tracks that are converted by broadcaster 68 into magnetic impulses for magnetic stripe emulation. Another embodiment includes one, three, four or more tracks. Broadcaster 68 includes one or more electrical coils for converting electrical signals into magnetic impulses.

  The broadcaster 68 in this example may further include one or more sensors 70 that are electrically connected to the general processor 52. These sensors are used to send to the general processor 52 that the physical action of inserting the card body 10 into the legacy card system has begun. The sensor 70 also communicates with the general processor 52 when it no longer contacts the magnetic stripe reader 72 that receives and reads the magnetic flux impulse from the broadcaster.

  As described above, the electronic card 10 in this example includes the electronic interface 16. In this example, electronic connector 16 is used in accordance with ISO 7816 for communicating with ISO 7816 reader device 74. That is, in this example, the electronic card 10 can be used as a legacy smart card or as a legacy magnetic stripe transaction card.

  When used in legacy smart card mode, secure processor 44 is powered by bus 48 from smart card reader device 74. The reader device 74 can be used to program and personalize the secure processor 44 with various information including, but not limited to, firmware code, account number, encryption key, PIN number, and the like. This information, once loaded into the secure processor 44, prepares the secure processor 44 for operational mode that no longer requires the use of the reader device 74.

  In this “independent” mode, the secure processor 44 communicates with the general processor 52 and authentication information used to communicate via the encryption function, the magnetic stripe emulator 64 with the general processor 52 and the magnetic stripe reader 72. Provides services such as dynamic generation of Again, the authorization code can be used only once for a single transaction. Subsequent transactions require a new authorization code to be generated. The secure processor 44 sends account information and / or DACs via RF and IR.

  In another example, the card body 10 continues to be used with the reader device 74 and the magnetic stripe reader device 72. In this example, the card retrieves the mode used and automatically switches the use of the bus 48 suitable for the retrieval mode of operation. This is accomplished by an optional bus arbitrator 76. In other embodiments, the bus arbitrator 76 is not present. Since power is supplied by the reader device 74 via the bus 48 from the electronic connector 16, any bus arbitrator 76 can search when used with the reader device 74. Similarly, the optional bus arbitrator 76 retrieves that power is being provided by the general processor 52 and operates to service the general processor 52 and the various I / O devices connected thereto. Switch to the corresponding mode. In other embodiments, the optional bus arbitrator 76 still allows dynamic communication with each other in both the general processor 52 and the secure processor 44 and with the reader device 74, respectively. This requires bus arbitration logic well known to those skilled in the art. In yet another embodiment, the general processor 52 interrupts between the secure processor 44 and the electronic connector 16. In this alternative embodiment, the general processor 52 operates as a “broker” or “front end” to the secure processor 44.

  With reference to FIG. 3, the desired contactless communication port 77 may alternatively or additionally be included in the desired communication ports 16 and 64. That is, the contactless communication port 77 can be provided to allow communication without physical contact with the reader.

  The contactless communication port 77 may be a radio frequency communication port, an IR communication port, or any other form of communication that does not require physical contact. Of course, other embodiments may be provided with contact communication ports, such as communication port 16 or broadcaster. That is, these embodiments are described as non-limiting examples.

  The radio frequency (“RF”) standard for smart card communications is ISO / IEC 14443 dated 2001. It includes antenna and RF driver characteristics, defines two types of contactless cards (“A” and “B”), and allows communication up to a distance of 10 cm. Proposals have been made for ISO 14443 types C, D, E, and F that have not yet completed the standardization process. Another criterion for contactless smart cards is ISO15693 which allows communication up to a distance of 50 cm.

  FIG. 4 shows another example of the secure processor 44 of FIG. 3 in more detail. The secure processor 44 in this example is a microcontroller including a power switch 78, a security sensor 80, a reset generator 82, a clock input filter 84, a CPU 86, an interrupt system 88, and an internal bus 90 in accordance with ISO 7816. Connected to the internal bus 90 is an unauthorized change prevention storage 46 composed of RAM, EEPROM or the like. Also connected to the bus 90 is a coprocessor 92 that performs encryption and decryption. In this preferred embodiment, co-processor 92 performs TRIPLE-DES encryption and decryption. Also connected to the bus 90 is a timer 94 and, for example, a secure processor 44, a ROM 96 used to store firmware for the UART 98 used for serial communication. Also connected to the bus 90 are an I / O system 100 and a random number generator 102.

  The secure processor 44 described above is commercially available from various manufacturers such as Philips, Hitachi, Infilion, Toshiba, ST and others. A secure processor 44 suitable for use in other disclosed embodiments is a model P8WE6032 processor manufactured by Philips, Germany. In one embodiment, secure processor 44 may be replaced with a general processor.

  FIG. 5 is a schematic diagram of a general processor 52 associated with the general processor 52 and connected to an I / O device system described as a non-limiting example. As previously mentioned, the general processor 52 may be a PIC16 or PIC18 microcontroller. For example, the general processor 52 may be a microchip LF77PIC16 or a microchip LF4530PIC18. Alternatives are provided by Texas Instruments, Atmel et al. Other general processors are also used in certain embodiments, and general processor 52 may also be a secure processor.

  In this preferred embodiment, two electrochemical batteries 121A and 121B are shown. As already mentioned, batteries of appropriate chemistry and size are commercially available from Varta Microbattery GmbH. In this example, the non-rechargeable battery 121A serves as the first battery, while the rechargeable battery 121B serves as the second battery. Battery 121B may be connected to a recharge device 122, shown as an RF power source. Of course, the induced current is rectified prior to being applied to battery 121B. As already mentioned, there are many other suitable recharging devices that will be apparent to those skilled in the art.

  Desirably, a capacitor assembly 124 is provided to provide a smooth power source with no peaks or output dropout. As shown, the capacitor assembly may include one or more capacitors. Capacitor assembly 124 may also be used for a smooth power supply from a rectifier present in recharger 122. Battery 121A, battery 121B, recharge device 122, and capacitor assembly 124 are all part of power source 56 of FIG. 3 in this embodiment.

  One or more capacitors, such as capacitor assembly 124, can also be used as a charge storage device. That is, a “supercapacitor” having sufficient capacity can significantly supplement the current supplied by the electrochemical battery in certain embodiments. For example, a capacitance range of approximately 1 uF + -10% @ 6.3v serves as a supercapacitor in some embodiments. This relatively large capacitor assembly 124 is conveniently accomplished, for example, by using ten 0.1 uF capacitors connected in parallel to reduce the size and height of the capacitor.

  While continuing to refer to FIG. 5, a temporary port 125 is provided to assist the manufacturing process. Optionally, it is provided on a portion of the printed circuit board that is removed once the manufacturing operation requiring its use is completed. The temporary port 125 can be used, for example, to load data and programs into the general processor 52 and associated EEPROM, as well as the secure processor 44 and associated EEPROM. Component 123 is provided to ensure that the electrical connection to general processor 52 has the proper electrical characteristics and eliminates output spikes, output dropouts, and the like.

  The general processor 52 is connected to many switches including the on / off switch 28 and the selector switch 38 in this embodiment. Also connected to the general processor 52 are a number of light emitting diodes (“LEDs”) including a “power-on” indicator 30, a “power-off” indicator 32, and an “account-on” indicator 36. These various LEDs and switches constitute the human / computer interface associated with electronic card 10. Of course, there are many alternatives and additions to the electronic card 10 and devices that communicate with the electronic card 10 that are also useful for human / computer interfaces. As a further non-limiting example, the electronic card 10 may include an LCD screen (with or without a touch panel), audio I / O, voice recognition, and various other alternatives that will be apparent to those skilled in the art.

  In this example, the RC buffering circuit 66 is connected to the general processor 52, and a magnetic signal ("dynamic magnetic flux") supplied by a magnetic stripe transaction card that passes a rectangular waveform signal generated from the general processor 52 through the reader. Into a waveform emulating (simultaneously with broadcaster 68 and / or other components). The waveform is electrically communicated to a broadcaster 68 that converts the electrical signal into a dynamic magnetic field that simulates passing through a magnetic stripe reader of a card having a magnetic stripe. The electronic card 10 can be moved or stopped, and the various magnetic fields broadcast by the broadcaster 68 emulate the various magnetic fields created by the magnetic stripe of a conventional transaction card that moves and passes through the readhead. To rate. The magnetic signal produced by the broadcaster therefore tends to be significantly uniform according to its length.

  Sensor 70 provides a signal to general processor 52 to indicate that the card has made physical contact with the reader. The sensor 70 may take various locks including physical switches, pressure sensors, or other alternatives that will be apparent to those skilled in the art. Broadcaster 68 obtains its waveform after operation of one or more sensors 70.

  Four desirable coils 128, 130, 132 and 134 are shown in FIG. In particular, in this preferred embodiment, broadcaster 68 includes a “track 1” coil 128, a “track 2” coil 130, a “track 1 cancelation” coil 132, and a “track 2 cancellation” coil 134. In this preferred embodiment, track 1 coil 128 and track 2 coil 130 are desirably placed on the card for optimal contact with the magnetic read head of magnetic stripe reader device 72 (see FIG. 3). In other words, the track 1 coil 128 is preferably interposed between the track 2 coil 130 and the track 2 cancelation coil 134 and arranged at an equal distance.

  Since the magnetic field from the track 2 coil 130 interferes with the magnetic field of the track 1 coil 128, the track 2 cancellation coil 134 is provided to “cancel” this “crosstalk” effect. “Cancel” reduces crosstalk at least significantly. The magnetic field generated by the track 2 cancellation coil 134 is the opposite of that of the track 2 coil 130, thus reducing the effect of the track 2 coil magnetic field on the track 1 coil 128. Similarly, the track 2 coil 130 is interposed between the track 1 coil 128 and the track 1 cancelation coil 132 in this example, and is equidistant from these. A reduction in the crosstalk effect of the track 1 coil 128 is provided by the track 1 cancellation coil 132. Broadcaster coils 128-134 and sensor 70 constitute broadcaster 68 in this preferred embodiment.

  In another embodiment, cancelation coils 134 and 132 are not provided, but rather the electrical signals supplied to these coils cause the disturbing magnetic field to provide an appropriate magnetic input to magnetic stripe reader device 72. It is corrected by the method of supplying. This may be accomplished through the use of an ASIC, a digital signal processor (DSP), or by other means. Optionally, these two broadcaster coils 126 can be offset from their position in the previously described embodiments to provide a suitable effect. Alternatively, cancellation can be achieved through mechanical shielding with nanomaterials that can shield broadcast data between two nearby coils. These various preferred embodiments are given as non-limiting examples. Alternatives to the embodiment shown in FIG. 5 will be apparent to those skilled in the art.

  In addition, the digitally synthesized signal is applied to a broadcaster 68 that can reduce or eliminate the need for signal conditioning circuitry such as RC circuitry and / or the need for a cancellation coil. This digitally synthesized signal is achieved, for example, in the general processor 52, in the DSP, or in other circuits that would be preferred by those skilled in the art.

  FIG. 6 is a plan view of a preferred printed circuit (PC) board 136. Desirably, the PC board 136 is a “flexible” board such that the electronic card 10 follows the ISO 7810 standard for flexibility described above. The PC board 136 is supplied with conductive wiring such as wiring 137 and assists various electronic components such as the processors 44 and 52. The PC board 36 also provides space for the broadcaster 68 and one or more electrochemical batteries 121. This preferred embodiment is given as a non-limiting example.

  As described above, the thickness (or height when the card is taken as a cross section) of the electronic card 10 made to meet the ISO 7810 size standard is only about 30 mils. Therefore, it is important that the various internal components of the electronic card 10 are thin, flat and substantially coplanar. As a non-limiting example, the digital processor 52 should be thin and flat with a first substantially planar surface and a substantially opposite second substantially planar surface. Also, a first maximum surface area should be defined. As a further non-limiting example, for the electrochemical battery 121, it should have a first substantially planar surface and a substantially opposite second substantially planar surface, The maximum surface area should be defined. The theoretical plane through the center of the digital processor 52 should be substantially coplanar with the theoretical plane through the center of the battery 121 so that the desired thickness of the electronic card 10 can be achieved. is there.

  As used herein, the term “substantially” means approximate. For example, a substantially planar surface is at least approximately flat. Minor defects, staircases, protrusions, and curvatures for large surfaces are still considered “substantially planar” and should not be applied to the entire surface. “Substantially opposing surfaces” are generally facing each other and at least approximately parallel.

  By “substantially coplanar”, the theoretical center plane is at least near and nearly parallel. Of course, the center plane of the processor 52 is above or below the center plane of the battery 121 and the two parts are “substantially coplanar” as long as the thinness of the electronic card 10 can be maintained. Conceivable. For example, processor 52 and battery 121 are considered to be in the same plane as long as there is a plane generally parallel to the large surfaces of these parts where both two parts intersect. If, for example, in cross section, battery 121 is 16 mils high and processor 52 is 10 mils high, the center planes of these parts can be separated by 8 mils, but they are still substantially coplanar. It is believed that there is.

  FIG. 7 is a bottom view of a preferred PC board 136. The PC board 136 is also provided by a number of wires 137 as well as a space for the broadcaster 68 and the battery 121. Also shown is an interface 16 that is geometrically arranged to coincide with the position of the secure processor 44. These preferred embodiments are given as non-limiting examples.

  The PC board 136 is, for example, a PC board having a multi-layer structure. For example, the top of the PC board 136 shown in FIG. 6 may be the first or top layer, and the bottom of the PC board as shown in FIG. 7 may be the second or bottom layer. The two layers may be fixed together or there may be other intermediate layers. Each layer includes an insulating substrate made of, for example, PVC material and can include conductive traces, pads, and other structures. As mentioned above, it is desirable that the PC board is flexible to help the electronic card 10 meet ISO 7810 standards for flexibility.

  FIG. 8 is a partial sectional view of the electronic card 10 and is an exploded view. The bottom cover 140 has a maximum height of about 25 mils in this example. It should be noted that the bottom cover 140 is contoured on its upper surface 141 to fit a PC board, battery, and / or components attached to the bottom of the PC board or the like. . The PC board 136 has a height of about 6 mils, which in this example is thin and flexible. The general processor 52 is shown mounted on a PC board 136 and encapsulated in a material 144 (eg, an epoxy resin encapsulant). Similarly, it is shown that the secure processor 44 is encapsulated in the material 144. Various components of the battery 121 are attached to the PC board 136.

  With continued reference to FIG. 8, a preferred embodiment of battery 121 has a height of 16 mils. Also shown in FIG. 8 is a broadcaster 68 that, in this embodiment, coincides with the battery 121 in the lateral direction and therefore occupies overlapping space in this cross-sectional view. The broadcaster 68 shown in this preferred embodiment has a height of about 20 mils. Further, an account selector switch 38, an “on” indicator 30, and an “off” indicator 32 are attached to the PC board 136. Account indicator 34 coincides with on indicator 30 in the lateral direction and therefore occupies overlapping space in this cross-sectional view.

  Cover 146 is shown at a height of about 5 mils. When assembled, the electronic card 30 is therefore approximately 30 mils according to ISO 7810. The preferred embodiment shown in FIG. 8 is provided as a non-limiting example and will vary in size as will be appreciated by those skilled in the art.

  FIG. 9 is a partial cross-sectional view of the electronic card 10 after being assembled. Various desirable components are shown in various layers in a compact configuration similar to the final electronic card 10. Covers 140 and 146 surround and protect the electrical and electronic circuitry within the card. Desirably, an epoxy based adhesive is used to encapsulate electrical and electronic components (other than those to be exposed) and hold the assembly together. Covers 140 and 146 may be constructed of polyester, or FR4, or various materials as described above. The final assembly is an electronic card 10 sealed in the size described by the ISO 7810 standard. Significantly, the thickness T should not exceed 30 mils to work properly with legacy card readers. Other embodiments provide electronic cards of different sizes and formats.

  FIG. 10 is a detailed front view of wire bonds connecting to the processor die 56 to the PC board 136. This preferred embodiment allows for an advantageous thinness due to the strict size constraints imposed by the thickness standard for the electronic card 10. The die 56 is mounted on the PC board 136 using an adhesive or other adhesive material 158 that constitutes the physical connection between the processor 56 and the printed circuit board 136. The wire 148 electrically connects the bonding pad 160 of the processor 56 to the bonding pad 160 of the PC board 136.

  It is very important that there is a low loop height “d” for the wire 148. Standard wire bonding techniques first bond the wire to the processor and then to the circuit board, resulting in a very high loop height. High loop height is unacceptable for electronic cards to be made very thin. Also, the high loop height creates reliability problems due to bending and torsional stresses on the electronic card.

  In accordance with this preferred example embodiment, a reverse bonding process is used in which wires 148 are first attached to PC board 136 and then to processor 56. This preferably results in a loop height “d” of less than 5 mils, more preferably as short as 2-4 mils. As a result, when “D” is the height of the top surface of the processor 56 on the PC board 136, the total height of the loop is equal to d + D. In this example, the processor die 56 is about 910 mils and the adhesive is about 1-2 mils, resulting in a height “D” of about 10-12 mils. If the loop height d is in the range of 2-4 mils, the total loop height on the top surface of the PC board will be in the range of 12-16 mils in this example.

  Low loop height also improves the bending and torsional stresses on the electronic card. For example, a loop height of less than 5 mils, more preferably less than 4 mils, and most preferably about 2 mils loop height achieves a tensile strength of 7-10 grams of wire. Can be done.

  In another embodiment, the processor 56 is attached to the PC board by a flip chip method. Techniques for attaching dies to circuit boards by flip-chip techniques are well known to those skilled in the art.

  FIG. 11 shows a receptacle 160 in the PC board 136 for the broadcaster 68. Broadcaster 68 in this example is plugged into receptacle 160 at a later stage in the manufacturing process and then electrically connected to contact pad 161. When the broadcaster 68 is mounted inside the receptacle 160, it is important that a high degree of geometric alignment be achieved so that the broadcaster 68 can be aligned with the card reader readhead. A guide 162 visible in the broadcaster 68 through the hole is provided to assist in this physical alignment process. When the broadcaster 68 is inserted into the slot 160, it is desirable to line up near the hole of the alignment guide 162 broadcaster 68. An optical microscope is used to assist in this process. Of course, these preferred embodiments are given as non-limiting examples, and other alignment techniques are suitable.

  FIG. 12 shows the broadcaster 68 in its final form before being inserted into the slot 160. A track 1 coil 128 and a track 2 coil 130 are arranged for proper contact with the magnetic stripe device 72. The track 1 canceling coil 132 and the track 2 canceling coil 134 are disposed so as to appropriately perform a crosstalk canceling function between the track 1 coil 128 and the track 2 coil 130. The sensor 70 is shown here as a trip switch that retrieves an event that the electronic card 10 is being passed through the magnetic stripe reader device 72.

  These preferred embodiments are given as non-limiting examples. Alternatives to the configuration and structure of broadcaster 68 will be apparent to those skilled in the art. For example, alternative embodiments are contemplated that do not include cancelation coils 132 and 134, and other alternative embodiments are possible. Another non-limiting example has only a single track coil.

  FIG. 13 shows a preferred broadcaster coil 128 in more detail. The other broadcaster coils 130-134 may be similar or identical in structure and may be different in alternative embodiments. In this embodiment, wire 164 is wound around ferromagnetic core 166. The wire 164 can be made of, for example, copper, aluminum, an alloy thereof, or the like. The wire 164 may be insulated, the core 166 may be insulated, or the core 166 may be insulated to avoid shorting the windings of the wire 164.

  In the preferred embodiment, the broadcaster core 166 is composed of a material called “HyMu80”, commercially available from National Electronic Alloys Inc, with the preferred magnetism. Single strand copper wire 164 is wound around broadcaster core 166 at regular intervals, for example, at a constant pitch “P”. In the preferred embodiment, the wire coil pitch is approximately 4.8 mils. This preferred embodiment is given as a non-limiting example, other pitches and variable pitches are suitable for certain embodiments.

  FIG. 14 shows the desired spacing of the wires 164 wound around the core 166. FIG. 14 shows that there is a regular spacing between each turn of the coil of copper wire 164 at a constant pitch. While other embodiments can be used, this is the preferred embodiment.

  FIG. 15 shows a slightly irregular winding method. Even if there is some error during the wire winding process, the resulting broadcaster coil is still in spite of some errors in the wire winding process as shown in FIG. Can be used. The pitch can also be variable to modify the magnetic flux pattern. However, if excessive errors enter during the production of broadcaster coil 126, then the coil may become inoperable. It has been found that if the change in pitch is excessively large, an error is introduced into the dynamic magnetic field created by the coil, resulting in improper operation of the electronic card 10 emulator embodiment.

  FIG. 16 illustrates an example of excessive error in the coil winding arrangement of the broadcaster coil 126. It is important to note that there are many variables that give rise to operability limits and that the broadcaster coil 126 should be tested to ensure proper quality. It is not necessary to test each and every coil, and the sampling of the broadcaster coil 128 should be tested to ensure that the manufactured bundle of coils works. 14-16 are given as alternative examples of coil windings and are not to be construed as limiting techniques.

  The above embodiment for the coil teaches winding a wire around a ferromagnetic core. In another embodiment, the coil can be made in other ways. For example, the coil can be made by various deposition, patterning and etching techniques. The ferromagnetic core can be coated with an insulating film and then, by way of non-limiting example, by means of sputtering and nano-sputtering techniques, such as copper, aluminum, or alloys thereof (usually metal) It will be understood by those skilled in the art that it is coated with a) layer. Thereafter, a mask is applied to the conductive layer to determine the coil, and portions of the conductive layer can be etched to provide a winding. The mask can be made photolithographically, for example, by spraying ink-jet techniques or techniques well known to those skilled in the art. Etching is accomplished with an acid that erodes the conductive layer but stops near the insulating layer. This method of coil manufacture can be advantageous in the context of mass production.

  For example, a ferromagnetic core can be provided and cleaned. The insulation and / or etch stop layer can be applied by a variety of techniques including, but not limited to, dipping, spraying, coating, sputtering, CVD, and the like. A metal or other conductive layer can then be applied again by various techniques including, but not limited to, dipping, spraying, sputtering, CVD, and the like. The mask layer can be applied as a photolithographic material by painting, printing, spraying, stenciling, etc. as would be understood by one skilled in the art. Etching of the conductive layer leading to the mask layer can be accomplished by a variety of techniques, including but not limited to dipping, spraying, immersing, and plasma etching techniques. The mask layer can then be removed and a passivating layer can be applied to protect the coil assembly.

  As will be appreciated by those skilled in the art, there are other ways to create the “coil” effect of a broadcaster. For example, a magnetic material can be lithographically sputtered to create a broadcaster coil effect. There are various mass production techniques, such as the examples described above, that will be apparent to those skilled in the art of semiconductor and micromachine manufacturing.

  FIG. 17 shows another example that allows the broadcaster 68 'to operate without a cancellation coil. Track 1 coil 128 and track 2 coil 130 are shown in broadcaster 68 '. The buffering circuit 66 'is designed in this embodiment to perform cancellation prior to the emission of the waveform to the track 1 coil 128 and the track 2 coil 130. The waveform is adjusted in such a way that all crosstalk effects between the track 1 coil 128 and the track 2 coil 130 produce the desired magnetic flux. This alternative embodiment cancels the crosstalk effect by modifying the waveform so that it is properly received by the magnetic stripe reader device 72. In this embodiment, buffering circuit 66 'may be an ASIC, DSP, or other suitable component for signal processing. Sensor 70 is present in this embodiment of broadcaster 68.

  In another preferred embodiment, general processor 52 comprises an ASIC chip that optionally includes one or more other components associated with transaction card 10. For example, the ASIC plays the role of the buffering circuit 66 as well as the role of other components associated with the general processor 52 in the previously disclosed embodiments. In addition, the ASIC embodiment can create modified waveforms for the track 1 coil 128 and the track 2 coil 130, such as eliminating the need to include the track 1 cancellation coil 132 or the track 2 cancellation coil 134, for example. it can. For example, the ASIC can apply the amplitude and phase correction of the track 1 coil 128 waveform due to the predicted effect of magnetic flux interference from the track 2 coil 130. Similarly, the correction can be applied to the track 2 coil 130 waveform to cancel the effect of the track 1 coil 128.

  Note that because the interference from the opposite broadcaster coil 126 can change over time (at different parts of the waveform), the correction applied to the waveform can change over time. Therefore, the modification constitutes two new waveforms for the two respective broadcaster coils 128 according to this preferred embodiment. It should also be noted that the waveform modification for a given broadcaster coil 128 will itself cause interference with the opposite broadcaster coil 128.

  In some preferred embodiments, additional modifications are applied to compensate for the effects of previous modifications. In a further preferred embodiment, one or more additional modifications are applied until the interference reduction effect becomes as negligible as the series converges. Note that these corrections are performed in a computerized manner before the corresponding portion of the waveform reaches the broadcaster 68.

  In yet another embodiment, crosstalk cancellation is performed by a linear RC circuit that outputs the modified waveform to track 1 coil 128 and track 2 coil 130. This RC circuit can be placed in the desired ASIC or can be placed outside the ASIC. Again, this example is given as a non-limiting example.

  FIG. 18 shows a manufacturing process for producing the electronic card 10. In operation 168, the first stage of the manufacturing process is performed. During this process, various parts are installed and programmed. Operation 170 continues with the second stage of this manufacturing configuration by installing additional components such as broadcaster 68 and battery 121. Finally, the manufacturing process is completed in the third stage with operation 172 performing epoxy filling.

  FIG. 19 shows the first stage 168 of the manufacturing method in more detail. In operation 174, the technical components are attached to the surface of the printed circuit with which they are associated. In operation 176, the die is attached. The aforementioned wiring bonding process is performed at operation 178 to electrically connect the die to the printed circuit board. Thereafter, in a programming step 180, the secure processor 44 and the general processor 52 are programmed with various data and programs necessary for the operation of the electronic card 10.

  Operation 182 performs a functional test prior to encapsulation to ensure that programming is successful and the various electrical connections are secure.

  In decision step 184, it is determined whether the functional test is passed. If not, after which control passes to operation 186 where the failure causing the failure is determined. Thereafter, in operation 188, the defect is reworked in operation 188, after which control passes again to programming step 180. On the other hand, if the function test is passed in decision step 184, then the encapsulation step is performed in step 190. The steps shown here are desirable and will be apparent to those skilled in the art, and many alternative embodiments may be used. That is, this process is described as a non-limiting example.

  FIG. 20 illustrates the programming operation 180 in more detail. Operation begins at operation 192 and continues to operation 194 where the electronic card 10 is attached to the test device. The test program is started on the test device at operation 196. The purpose of this test program is to load data and programs into the technical components of the electronic card 10, such as the secure processor 44 and the general processor 52.

  In operation 198, the test program is initialized. This includes loading parameters and settings from various files and getting them from the user. Operation 200 performs the actual loading of software and data on the technical component. Thereafter, in operation 202, the process ends. This step is illustrated by the preferred embodiment and should not be considered in a limited way.

  FIG. 21 illustrates operation 200 of FIG. 20 in more detail. This operation is used to load software and data into the technical components of the electronic card 10. The operation begins at operation 204 and continues to operation 206 which opens a file containing the code and data to be loaded. Thereafter, in operation 208, an address range for a particular data block is obtained. This address range is used when communicating with the secure processor 44 and the general processor 52 to clearly prove the location of the EEPROM where this particular data block is to be stored. As will be appreciated by those skilled in the art, the data may constitute a program. In operation 200210, a message including block data and address information is formatted. Thereafter, in operation 212, a message is sent. Operation 214 receives and records status information. Decision operation 216 determines whether the last block has been sent or whether the process has been terminated for other reasons, such as in the case of an error. If it is determined that the loading operation should continue, control returns to operation 208. If in operation 216 it is determined that the process should end, control passes to operation 218 which reports the status of the loading operation, after which the process ends at operation 220.

  FIG. 22 shows the second stage of manufacturing operation 170 in more detail. The process begins at operation 222 and continues to operation 224 where a functional test is performed on the device. In decision operation 226, it is determined whether the functional test is passed, and if not, control passes to operation 228 where corrective action is taken. Control then returns to operation 224. If in operation 226 it is determined that the functional test is passed, control passes to operation 228 where the dome switch is taped and the via switch is soldered. Thereafter, in operation 230, the broadcaster 68 is installed in a slot supplied in the electronic card 10. Thereafter, in operation 232, the battery 121 is installed. In operation 234, the assembly is inspected and tested. If in operation 234 it is determined that the assembly is not functionally appropriate, control passes to operation 236 where corrective action is taken. Control then returns to operation 234. If in operation 234 it is determined that the assembly is operating correctly, control passes to operation 236 where the process ends. These preferred embodiments are given as non-limiting examples.

  FIG. 23 describes the third stage 172 of the manufacturing process. Then, beginning at operation 238, operation 240 continues where the assembly of electronic card 10 is filled with epoxy resin, laminated and tested. Thereafter, in operation 242, various sized assemblies are employed, and a decision step 244 determines whether the assembly needs to be reworked. If in operation 244 it is determined that the assembly should be reworked, operation 246 is taken and control is returned to operation 244. If in operation 244 it is determined that no rework of the assembly is required, control is passed to operation 246 which terminates the process.

  The preferred manufacturing process and variations described above are used in various embodiments of the transaction card 10. For example, manufacturing process variations use photolithography techniques well known to those skilled in the art to produce broadcasters 68. This method avoids the use of coil wiring, which can save time and money when manufacturing a large number of transaction cards 10.

  Another process variation uses a “flip-chip” method, well known to those skilled in the art, to attach one or more technical components, such as general processor 52. Optionally, this variation includes the use of an ASIC as the general processor 52. This example is given as a non-limiting example. Another preferred embodiment of the contactless communication port 77 of FIG. 3 constitutes a WiFi device or equivalent such that the transaction card 10 of this embodiment can communicate over the Internet independently of the card reader. By way of non-limiting example, WiFi 802.11b and 802.11g protocols may be used.

  The card can periodically download and upload information and perform transactions in response to user input. Information from the Internet can be displayed to the user, and in some embodiments, exchange on the World Wide Web is also possible. This embodiment desirably includes an LCD display or equivalent, and a touch screen or equivalent. This example is given as a non-limiting example.

  Although various embodiments have been described with specific terms and apparatus, such description is for illustrative purposes only. The terms used are descriptive terms rather than limiting. It will be understood that changes and modifications may be made by those skilled in the art without departing from the spirit and scope of the invention as described in the claims. In addition, it should be understood that aspects of various other examples may be interchanged in whole or in part. Therefore, the claims are construed according to the essence and scope of the invention, excluding limitations or estoppel.

  The industrial applicability of the present invention is an improved electronic card for financial and other purposes, and a method of manufacturing the same.

FIG. 1 is a plan view of a desirable electronic card. FIG. 2 is a bottom view of the preferred electronic card of FIG. FIG. 3 is a block diagram relating to a desirable circuit for the electronic card shown in FIGS. 1 and 2. FIG. 4 is a block diagram of the preferred secure processor of FIG. FIG. 5A is a schematic diagram of a preferred embodiment of the general processor of FIG. 3 and a preferred embodiment of associated I / O devices and subsystems. FIG. 5B is a schematic diagram of a preferred embodiment of the general processor of FIG. 3 and a preferred embodiment of associated I / O devices and subsystems. FIG. 6 is a plan view of a printed circuit (PC) board of a desirable electronic card. FIG. 7 is a bottom view of the PC board of FIG. FIG. 8 is an exploded partial cross-sectional view of a desirable electronic card. FIG. 9 is a partial cross-sectional view after the electronic card of FIG. 8 is assembled. FIG. 10 illustrates a desirable wire bond connection between the processor and the PC board. FIG. 11 shows a preferred broadcaster with line row marks. 12 is a plan view of the broadcaster before being inserted into the broadcaster slot shown in FIG. FIG. 13 shows a preferred broadcaster coil. FIG. 14 shows a desirable winding pattern of the broadcaster coil of FIG. FIG. 15 shows a desirable winding pattern of the broadcaster coil of FIG. FIG. 16 shows a desirable winding pattern of the broadcaster coil of FIG. FIG. 17 is a block diagram according to another embodiment of a broadcaster assembly, described as a non-limiting example. FIG. 18 is a flowchart relating to a manufacturing process for producing an electronic card, which is described as a non-limiting example. FIG. 19 is a flow diagram showing in more detail the desired stage I manufacturing process 16 of FIG. FIG. 20 is a flow diagram illustrating in more detail the preferred programming process 180 of FIG. FIG. 21 is a flow diagram illustrating the “load software and / or data to chip” step 200 of FIG. FIG. 22 is a flow diagram illustrating in more detail the desired stage II manufacturing process 170 of FIG. FIG. 23 is a flow diagram showing in more detail the desired stage III manufacturing process 172 of FIG.

Claims (21)

A substantially planar first surface and a substantially opposite substantially planar second surface, wherein at least one of the first surface, the second surface, and a cross-section is a maximum surface An electronic card containing a thin, flat digital processor defining an area,
At least one of the first surface, the second surface, and the cross-section of the processor having a substantially planar first surface and a substantially opposite substantially planar second surface; A thin, flat electrochemical battery, one defining a maximum surface area, substantially coplanar with the processor and capable of supplying power to the processor;
A communication port connected to the processor;
A first flexible cover and an opposing second flexible cover, each having a surface area greater than the combined maximum surface area of the digital processor and the battery;
The electronic card, wherein the processor and the battery are sandwiched and surrounded by the first flexible cover and the second flexible cover.   The electronic card according to claim 1, further comprising a flexible circuit board including a plurality of wirings, wherein the processor is electrically connected to wirings of the circuit board.   The electronic card according to claim 1, wherein at least the processor is encapsulated.   The electronic card of claim 2 or 3, wherein at least one of the first cover and the second cover is contoured to fit over the entire circuit board, processor and battery.   The electronic card according to claim 2, further comprising a switch connected to the circuit board.   The electronic card according to claim 2, further comprising an indicator connected to the circuit board.   The electronic card according to claim 2, wherein the processor is electrically connected to wiring of the circuit board by a flip chip method.   7. The processor of claim 2 wherein the processor is electrically connected to the wiring of the circuit board by a wire having a first end bonded to the circuit board and a second end bonded to the processor. The electronic card of any one of Claims.   9. The electronic card of any one of claims 1 to 8, further comprising a capacitor connected to the battery to provide additional charge storage. Making flexible printed circuit boards,
Attaching at least one processor to the printed circuit board;
Connecting at least one battery to the printed circuit board;
Encapsulating at least one said processor;
Making top and bottom covers;
An electronic card manufacturing method comprising: sandwiching the printed circuit board, the processor, and the battery between the top cover and the bottom cover. A card body comprising an externally accessible card interface including a signal port, a power port, and a ground port; and at least partially disposed within the card body and connected to the signal port, the power port, and the ground port An improved smart card including a secure processor,
A general processor disposed at least partially within the card body, when connected to a power source disposed at least partially within the card body and the secure processor is used in an improved smart card mode A general processor that operates to supply power to the secure processor and communicate with the secure processor, and a contactless communication port connected to at least one of the secure processor and the general processor. Improved smart card to do. A card body,
A secure processor disposed at least partially within the card body;
A general processor disposed at least partially within the card body;
A power source disposed at least partially within the card body;
A secure transaction card comprising: the secure processor; and a contactless communication port connected to at least one of the general processors. A coil comprising an elongated core material and a winding having a plurality of turns around the core material;
A swipe emulator including a signal generator having a broadcast driver signal connected to the coil to allow the coil to provide a dynamic magnetic field that emulates the insertion of a magnetic stripe transaction through the read head of the card reader. Rating broadcaster system.   14. The swipe emulating broadcaster according to claim 13, wherein the signal generator includes a processor having a digital output and a signal processing circuit that converts the digital output to the broadcaster driver signal.   The swipe emulating broadcaster system of claim 13, wherein the signal generator is a digital signal processor.   The swipe emulating broadcaster according to claim 13, wherein the coil is a plurality of coils.   The swipe-emulating broadcaster according to claim 16, wherein at least one of the plurality of coils is a track coil.   The swipe-emulating broadcaster according to claim 16, wherein at least one of the plurality of coils is a cancellation coil.   The swipe-emulating broadcaster according to claim 13, wherein the coil includes a wire wound around the core.   The swipe emulated broadcaster according to claim 13, wherein the coil includes a wire formed around the core by a process including at least deposition of a conductive material and etching of the conductive material.   A first surface of the assembled semiconductor is attached to a first surface of a circuit board having a plurality of circuit board contact pads, and the second surface of the die facing the first surface is a plurality of die contacts. Exposing the pad to provide access to the pad; wire bonding the first end of the wire to the circuit board contact pad; and connecting the second end of the wire to the die contact pad. And wire loop height is equal to 5 mils on the second surface of the die and is equal to 20 mils on the first surface of the circuit board. How to create a low-loop bond for thin contouring applications including to become.

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