Manufacturing method of electrical bridges suitable for reel to reel mass manufacturing

• US 8,931,166 B2
• Filed: 05/21/2012
• Issued: 01/13/2015
• Est. Priority Date: 05/19/2011
• Status: Active Grant

• Current Assignee: Tecnomar Oy
• Original Assignee: Tecnomar Oy
• Inventors: Marttila, Tom
• Primary Examiner(s): TRINH, MINH N
• Application Number:
  US13/881,987
• Publication Number:
  US 20130220689A1
• Time in Patent Office: 967 Days
• Field of Search: 29 2535- 2542, 29846-847, 29829-831, 3405721-5729, 343/868, 343/700.MS, 361736-737
• US Class Current: 29/829
• 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 19/07783 the coil being planar
• CPC Class Codes: H01L 23/49855 for flat-cards, e.g. credit cards cards per se G06K19/00
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H05K 2201/0397 Tab
• CPC Class Codes: H05K 2201/1028 Thin metal strips as connectors or conductors
• CPC Class Codes: H05K 3/46 Manufacturing multilayer circuits
• CPC Class Codes: H05K 3/4685 Manufacturing of cross-over conductors
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49124 On flat or curved insulated base, e.g., printed circuit, etc.

Abstract

A manufacturing method of electrical bridges, wherein a conductive pattern (2) from electroconductive material, such as metal foil, is applied over a substrate (1) made of electrically insulating material and the electroconductive material has at least one strip tongue (3) unattached to the substrate, one side of the tongue is attached to the conductive pattern (2), and the said strip tongue (3) is folded over an area insulated electrically from the conductive pattern (2), and the strip tongue (3) is connected electroconductively to a predetermined other part (5) of the conductive pattern (2).

Claims

1. A reel to reel manufacturing method of electrical bridges or lead-ins over a substrate made of electrically insulating material, the method comprising:

patterning a conductive pattern from electroconductive material and at least one strip tongue made of the electroconductive material and unattached to the substrate,

wherein one side of the at least one strip tongue is attached to the conductive pattern;

folding the at least one strip tongue over a folded over area of the conductive pattern such that the folded over area of the substrate is electrically insulated from the strip tongue; and

connecting electro-conductively the strip tongue to a predetermined part of the conductive pattern.

2. The method as claimed in claim 1, wherein the strip tongue is folded over the conductive pattern on a same side of the substrate as the one side of the at least one strip tongue, wherein the method further comprises:

electrically insulating using the electrically insulating material between the conductive pattern and the strip tongue before the folding of the strip tongue,

wherein the electrically insulating material is a printing insulating varnish or glue on the area.

3. The method as claimed in claim 1, wherein, before folding the strip tongue, the strip tongue is attached at a second location, different from the one side of the strip tongue around which the strip tongue is folded,

wherein the second location is at least one the conductive pattern, an adjacent conductive pattern, a part of the foil attached to the substrate, and the substrate, and

wherein the method comprises:

detaching the strip tongue at the second location before folding or in connection with the folding of the strip tongue.

4. The method as claimed claim 1, wherein a shape and size of the strip tongue is selected so as to be appropriate for folding, and wherein the strip tongue is shaped after the folding either as a separate step or in connection with another step.

5. The method as claimed in claim 1, wherein the strip tongue of has a longitudinal extent parallel to a longitudinal extent of a plurality of strip tongues of conductive patterns on top of the substrate.

6. The method of claim 5, wherein the longitudinal extent of the at least one strip tongue is parallel to a movement of a web on a production line, wherein the method further comprises:

utilizing the movement of the web on the production line in the folding of the at least one strip tongue.

7. The method as claimed in claim 1, wherein the strip tongue is folded by suction, blasting, brushing, folding the laminate around a roll, pressing the strip tongue with a roll, bar or spring, or a combination of foregoing.

8. The method as claimed in claim 1, wherein the electrical insulation is provided between the folded strip tongue and the conductors remaining under the strip tongue by printing insulating varnish or insulating glue in the desired areas.

9. The method of claim 8, further comprising connecting the at least one strip tongue to the predetermined part by gluing with insulating glue.

10. The method as claimed in claim 1, wherein the strip tongue is connected to the predetermined part isotropically or by anisotropically electroconductive glue, paste or tape.

11. The method of claim 10, further comprising fixing the at least one strip tongue to insulation over the folded over area.

12. The method as claimed in claim 1, further comprising:

after the folding, electro-conductively connecting the at least one strip tongue to a second predetermined part of the conductive pattern.

13. The method of claim 12, wherein the connecting of the at least one strip tongue to the second predetermined part is by ultrasound or laser spot welding, or is by crimped connection.

14. The method as claimed in claim 12, wherein the insulation covers the predetermined part to be connected, and connecting of the strip tongue is performed such that the connection penetrates the insulation of the conductive patterns or the insulating substrate.

15. The method as claimed in claim 1, wherein the method further comprises:

covering, with a protective layer, a finished bridge formed by the at least one strip tongue, such that the protective layer secures the finished bridge to remain in place.

16. The method of claim 15, wherein the protective layer is varnish or an adhesive label.

17. The method of claim 15, wherein the protective layer prevents adhesive of the bridge to a surface of the laminate when the laminate is reeled onto a reel.

18. The method of claim 1, wherein the at least one strip tongue is patterned from metal foil.