Transponder layer and method for the production thereof

A method for producing a transponder layer for use in a multi-layer laminated chip card, the transponder layer comprising an antenna substrate including a wire conductor having a substantially round cross-section embedded with a portion of its cross-section in an elongate layer of plastic and the remaining portion of the wire conductor cross-section protruding from the elongate layer of plastic, wherein the antenna substrate comprises a first side comprising a plastic surface, and a second side including a protruding metal conductor, said method comprising:

• removing plastic from the first side of the antenna substrate to form a chip accommodation window sized and dimensioned to receive a package-less chip, the chip accommodation window exposing portions of the metal conductor to the first side of the antenna substrate, wherein flat contact portions are formed in the exposed portions of the wire conductor in the chip accommodation area;
• positioning the chip accommodation window adjacent a mounting plate;
• inserting a package-less chip in the chip accommodation window with a surface of the package-less chip including terminal contacts contacting the exposed portions of the metal conductor in the chip accommodation window;
• heating the wire conductor;
• and
• applying pressure to the package-less chip from the first side of the plastic substrate, wherein the terminal contacts of the chip directly contact the flat contact portions of the wire conductor, and the chip is accommodated in the antenna substrate with the side of semiconductor body opposite the surface including terminal contacts flush with the first side of the antenna substrate.