Method of manufacturing an electronic card

1. A method of manufacturing an electronic card including a biometric sensor, the method comprising:

providing a preformed card body including a circuit having contacts configured to connect to the biometric sensor, the contacts being embedded within the preformed card body; and

forming a cavity in the preformed card body to expose the contacts.

2. A method as recited in claim 1 , further comprising:

installing a biometric sensor in the cavity.

3. A method as recited in claim 2 , wherein the biometric sensor is a fingerprint reader.

4. A method as recited in claim 2 , further comprising:

connecting the biometric sensor to the contacts using a conductive epoxy.

5. A method as recited in claim 4 , wherein the conductive epoxy is an anisotropic conductive epoxy.

6. A method as recited in claim 2 , further comprising:

coating the walls of the cavity with an adhesive epoxy prior to installing the biometric sensor.

7. A method as recited in claim 1 , wherein forming the cavity comprises removing material from the preformed card body to form the cavity.

8. A method as recited in claim 7 , wherein the material is removed from the preformed card body using a precision end mill or a laser mill.

9. A method as recited in claim 1 , wherein providing the preformed card body comprises forming the preformed card body using a hot lamination process.

10. A method as recited in claim 9 , wherein the hot lamination process comprises:

providing a first plastic layer;

providing the circuit on the first plastic layer, the circuit having the contacts for connection to the biometric sensor;

providing a second plastic layer on the first plastic layer with the circuit interposed between the first plastic layer and the second plastic layer; and

laminating the first plastic layer and the second plastic layer to form the preformed card.

11. A method as recited in claim 9 , wherein the laminating is performed at a temperature of at least 135° C. and/or a pressure of at least 5 MPa.

12. A method as recited in claim 1 , wherein the electronic card is any one of: an access card; a credit card; a debit card; a pre-pay card; a loyalty card; an identity card; and a cryptographic card.

13. An electronic card including a circuit having contacts and a biometric sensor connected to the contacts, the electronic card having been formed by a method as recited in claim 1 .

14. An electronic card, comprising:

a card body;

a circuit embedded within the card body, the circuit having contacts;

a cavity in the card body that exposes the contacts; and

a biometric sensor mounted within the cavity and electrically connected to the contacts.

15. An electronic card as recited in claim 14 , wherein the biometric sensor is electrically connected to the contacts by a conductive epoxy.

16. An electronic card as recited in claim 15 , wherein the conductive epoxy is an anisotropic conductive epoxy.

17. An electronic card as recited in claim 14 , wherein the biometric sensor is a fingerprint reader.

18. An electronic card as recited in claim 14 , wherein the circuit includes:

a memory arranged to storing biometric information relating to at least one authorised user of the card; and

a processor arranged to compare the stored biometric information to biometric information acquired by the biometric sensor to determine if a user of the card is one of the at least one authorised users.

19. An electronic card as recited in claim 14 , wherein the electronic card is arranged to be inoperable if the processor does not indicate an authorised user.