Process for assembling a coil on a printed circuit

• US 5,649,352 A
• Filed: 03/31/1995
• Issued: 07/22/1997
• Est. Priority Date: 04/19/1990
• Status: Expired due to Term

• Current Assignee: Assa Abloy AB
• Original Assignee: Sokymat
• Inventors: Gustafson, Ake
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US08/414,314
• Time in Patent Office: 844 Days
• Field of Search: 29/605, 29/805, 140/92.1, 140/93, 242/439, 242/439.2, 242/439.4, 242/440.1, 336/192
• US Class Current: 29/605
• CPC Class Codes: G06K 19/07749 the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card
• CPC Class Codes: G06K 19/0775 arrangements for connecting the integrated circuit to the antenna
• CPC Class Codes: G06K 19/07779 the inductive antenna being a coil
• CPC Class Codes: G06K 19/07781 the coil being fabricated in a winding process
• CPC Class Codes: H01F 41/074 Winding flat coils
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path

Abstract

The process for assembly of a coil with or without a core on a printed circuit comprises placing the printed circuit in the winding machine before starting the winding. When the Flyer brings the wire for the winding, it causes the latter to pass over a metallized path of the printed circuit while keeping said wire taut. After the Flyer has effected the number of turns necessary for the winding, it will carry the wire along, passing onto a second metallized path, always keeping it taut. The soldering of the two end wires of the winding on the respective metallized paths will take place very easily since each of said wires is held taut at the location where the soldering is to take place. This process permits automating the production of miniaturized electronic circuits comprising a winding.

Claims

1. A process for assembling a coil of wire on a core onto a printed circuit, wherein:

the printed circuit comprises;

two metallized paths for receiving ends of the wire,

a portion for physically attaching the core to the printed circuit, and

a plurality of holes formed in said portion of the printed circuit; and

the core is formed of a synthetic material and comprises;

a cylindrical barrel,

a front flange,

a rear flange,

a plurality of pins provided on an outside surface of the rear flange, and

a pair of notches provided in the rear flange opposite the two metallized paths;

the process comprising;

placing the printed circuit into a winding machine, the metallized paths being accessible for soldering the wire ends thereto;

inserting the plurality of pins into the plurality of holes to physically attach the core to the printed circuit such that the pair of notches provide access to the two metallized paths;

forming the coil on the core adjacent to the printed circuit each one of the wire ends passing over a corresponding one of the metallized paths of the printed circuit; and

soldering each one of the wire ends to the corresponding one of the metallized paths.

2. The process of claim 1, wherein the coil is formed with a flyer, and the wire ends are kept taut during the forming and soldering steps.

3. The process of claim 1, wherein the printed circuit has at least one electronic component attached thereto prior to the placing step.

4. The process of claim 2, further comprising the step of cutting or tearing off the wire ends beyond points where they are soldered to the metallized paths.

5. The process of claim 4, further comprising, prior to the cutting or tearing step, the steps of:

placing a second printed circuit into the winding machine;

forming a second coil adjacent the second printed circuit with the flyer, wire ends of the second coil being kept taut, and each one of the wire ends of the second coil passing over a corresponding one of two metallized paths of the second printed circuit; and

soldering at least a first one of the wire ends of the second coil on the corresponding one of the two metallized paths of the second printed circuit.

6. The process of claim 1, wherein the soldering is performed automatically.

7. The process of claim 2, wherein the flyer includes a tubular applicator for dispensing the wire.

8. A process for assembling a coil of wire, formed on a synthetic core onto a printed circuit, wherein:

the printed circuit comprises;

two metallized paths for receiving ends of the wire,

a portion for physically attaching the core to the printed circuit; and

a plurality of holes formed in said portion of the printed circuit; and

the synthetic core comprises;

a cylindrical barrel,

a front flange,

a rear flange,

a plurality of pins provided on an outside surface of the rear flange, and

a pair of notches provided in the rear flange opposite the metallized paths;

the process comprising;

inserting the plurality of pins into the plurality of holes to physically attach the core to the printed circuit such that the pair of notches provides access to the two metallized paths;

placing the printed circuit into a winding machine, the metallized paths being accessible for soldering the wire ends thereto;

forming the coil on the core by winding the wire around the core between the front and rear flanges, each one of the wire ends passing over a corresponding one of the metallized paths of the printed circuit; and

soldering each one of the wire ends to the corresponding one of the metallized paths.

9. The process of claim 8, wherein the coil is formed with a flyer, and the wire ends are kept taut during the forming and soldering steps.

10. The process of claim 8, wherein at least one electronic component in addition to the core is attached to the printed circuit prior to the placing step.

11. The process of claim 9, further comprising the step of cutting or tearing off the wire ends beyond points where they are soldered to the metallized paths.

12. The process of claim 11, further comprising, prior to the cutting or tearing step, the steps of:

physically attaching a second core to a second printed circuit;

placing the second printed circuit into the winding machine;

forming a second coil on the second core with the flyer, wire ends of the second coil being kept taut, and each one of the wire ends of the second coil passing over a corresponding one of two metallized paths of the second printed circuit; and

soldering at least a first one of the wire ends of the second coil on the corresponding one of the two metallized paths of the second printed circuit.

13. The process of claim 8, wherein the soldering is performed automatically.

14. The process of claim 9, wherein the flyer includes a tubular applicator for dispensing the wire.

15. An automated method for manufacturing a passive transponder device, comprising:

bonding an electronic device comprising at least one integrated circuit chip onto a printed circuit, the printed circuit comprising;

a plurality of metallized paths having first portions and second portions, and

a plurality of holes formed in said second portions of the metallized paths;

electrically connecting the electronic device to the metallized paths of the printed circuit;

encapsulating the electronic device and the first portions of the metallized paths in a plastic material such that the second portions of the metallized paths protrude therefrom;

forming a coil by winding a conductive wire around a core, the core formed of a synthetic material and comprising;

a cylindrical barrel,

a front flange,

a rear flange,

a plurality of pins provided on an outside surface of the rear flange, and

a pair of notches provided in the rear flange opposite6 the second portions of the two metallized paths;

inserting the plurality of pins into the plurality of holes to physically attach the core to the printed circuit such that the pair of notches provides access to the two metallized paths; and

conductively connecting wire ends of the wire to said second portions of the metallized paths.

16. The process of claim 15, wherein the coil is formed with a flyer, such that the wire ends are kept taut during the forming and conductively connecting steps.

17. The process of claim 16, further comprising the step of cutting or tearing off ends of the wire beyond points where the wire is conductively connected to said second portions of the metallized paths.

18. The process of claim 17, further comprising, prior to the cutting or tearing step, the steps of:

bonding a second electronic device comprised of at least one integrated circuit chip onto a second printed circuit comprising a plurality of metallized paths;

electrically connecting the second electronic device to the metallized paths of the second printed circuit;

encapsulating the second electronic device and first portions of the metallized paths of the second printed circuit in a plastic material such that second portions of the metallized paths of the second printed circuit protrude therefrom;

forming a second coil of wire by winding said conductive wire around a second core with the flyer, wire ends of the second coil being kept taut; and

conductively connecting at least a first one of the wire ends of the second coil to a corresponding one of said second portions of the metallized paths of the second printed circuit.

19. The process of claim 16, wherein the step of winding the conductive wire around the core comprises rotating the flyer around the core at high rpm.

20. The process of claim 15, wherein the soldering is performed automatically.

21. The process of claim 15, wherein the flyer includes a tubular applicator for dispensing the wire.