Flexible card with fingerprint sensor

A biometric system on card, comprising:

• at least one bottom lamination layer;
• a prelam layer disposed over the at least one bottom lamination layer, the prelam layer comprising:
• a flexible circuit substrate;
• a fingerprint sensor disposed on the flexible circuit substrate, the fingerprint sensor having upper and bottom surfaces, the bottom surface of the fingerprint sensor disposed on said substrate, an active layer of the fingerprint sensor disposed towards the upper surface of the fingerprint sensor;
• a first integrated circuit chip disposed on said substrate and having at least one lead electrically connected to the flexible circuit substrate;
• and
• an adapter flexible circuit electrically bonded to the active layer at the upper surface of the fingerprint sensor, wherein the first integrated circuit chip is adapted to communicate with the fingerprint sensor through the adapter flexible circuit;
• and
• at least one top lamination layer, the top lamination layer having a window formed therein overlying the fingerprint sensor.

A method of forming prelam layers for use in forming laminated cards, comprising the steps of:

• providing a flexible circuit substrate sheet having a plurality of areas corresponding to individual cards, each card area having:
• a fingerprint sensor disposed on the flexible circuit substrate sheet, the fingerprint sensor having upper and bottom surfaces, the bottom surface of the fingerprint sensor disposed on said substrate sheet, an active layer of the fingerprint sensor disposed towards the upper surface of the fingerprint sensor, and
• a first integrated circuit chip disposed on said flexible circuit substrate sheet;
• disposing an adapter flexible circuit sheet over the flexible circuit substrate sheet;
• electrically bonding the adapter flexible circuit sheet to the active layer of each fingerprint sensor;
• and
• after the bonding step, cutting the adapter flexible circuit sheet and flexible circuit substrate sheet into a plurality of individual prelam layers, each individual prelam layer comprising one or more of the plurality of areas corresponding to individual cards, each individual prelam layer having a respective flexible circuit substrate and adapter flexible circuit electrically bonded to the flexible circuit substrate, wherein the integrated circuit chip of each individual prelam layer is adapted to communicate with the fingerprint sensor of the each individual prelam layer through the respective adapter flexible circuit.