PCMCIA card manufacturing process

A PCMCIA card manufacturing process comprising the following steps:

• (1) providing a first cover member and a second cover member which are identical members made of metal plates, each of the cover members being in the form of a rectangle having two lateral edges on each of which an edge flange is formed with a, plurality of inward facing hooks mounted thereto;
• (2) Placing the first and second cover members respectively into a first mold and a second mold to injection mold a first frame member and a second frame member onto the first and second cover members, each of the frame members having a U-shape with two legs separated a distance suitable to be accommodated between the two edge flanges of the associated cover member so as to have the hooks of the associated cover member embedded within the legs during the injection molding process to respectively define a first frame/cover sub-assembly and a second frame/cover sub-assembly, each of the U-shaped frame members comprising a bottom portion connecting between the two legs to form the U-shape and each of the bottom portions having at least a notch formed thereon, corresponding to each other;
• (3) Disposing a circuit board and associated electronic elements between the two sub-assemblies with at least a connector which is electrically connected to the circuit board received within the at least one notch formed on one of the sub-assemblies;
• and
• (4) Mating the first and second sub-assemblies to have the at least one notch that is formed on each of the bottom portions of the U-shaped frame members match each other to define at least a connector slot for receiving and retaining the connector therein and securing the two sub-assemblies together to form the PCMCIA card.