WO2006000068A1

WO2006000068A1 - Process to manufacture transponder and the corresponding production equipment

Info

Publication number: WO2006000068A1
Application number: PCT/BR2004/000099
Authority: WO
Inventors: Milton Flávio MACEDO
Original assignee: Global ID South América Ltda.
Priority date: 2004-06-23
Filing date: 2004-06-23
Publication date: 2006-01-05

Abstract

Process to manufacture transponder and the corresponding production equipment constituted by an automated industrial manufacturing process for transponders or other similar electronic components, in which a microprocessed and robot equipment is used to perform various functions and stages of industrial production automatically and continuously, using for that a sequence of vertical (16) and horizontal rotating tables (6) and (18), through which a small tool or magnetic mold (13) runs, around which a metal wire is coiled and soldered by pressure to a small chip (4) and receives external protection or encapsulation by means of a bath of photopolymerizable liquid resin (17), being different from the other industrial processes by the magnetic tool or magnetic mold (13) which follows the whole production path for the component, being unitary during its manufacture and reused after taking the finished product from inside it.

Description

PROCESS TO MANUFACTURE TRANSPONDER AND THE CORRESPONDING PRODUCTION EQUIPMENT has the object of a practical and innovative process to manufacture transponders, included in the field of industrial manufacturing equipment, more precisely for use in the manufacture of electronic equipment such as microtransmitters, to which original constructive assembly has been given so to enhance its use and performance over other models usually found in the market. We therefore have, in the patent application at issue, a process and its corresponding equipment, especially projected and developed to reach huge practicality and bringing in huge advantages, both for its use and its manufacture. It is also an object of this application to present a fully automated manufacturing process, having low costs for its industrial execution, but added to the requirements of strength, safety and utility practicality, thus offering to the industries in the field an additional option in the market of similars. As widely known, technological development has taken mechanical processes and industrial manufacturing handbooks to make use of self-sufficient robot equipment to execute repetitive tasks with great precision. As known, notably by experts in the art, in the current processes a few items of serial manufacture still depend on old and costly processes, since its automation would require the use of a huge amount of money, besides the development and creation of parts and machines which are not yet available in the market. Usually, these production lines for small and delicate electronic components make use of huge human handwork and a few much high-cost and delicate machines executing small parts of manufacture of the produced item. The huge inconvenient of these current production systems is specifically the low productivity and handwork cost which is added to the final sale price of the product, besides the low quality of the manufactured component. Thinking of these inconveniences, after numerous researches and studies, the inventor, who is involved in this field, created and developed the manufacturing process and production equipment which are the object of this patent, by creating an integrated and automated system for the production of the electronic component as mentioned, in which not only mechanical and functional qualities were considered in the project of its manufacture, but also the shape, assembly and location of its parts and components which, when correctly positioned, brought an increase in efficiency, not bringing any cost. Therefore, this patent was projected with the aim to obtain a manufacturing process and its respective production equipment with the lowest possible number of parts, conveniently configured and assembled to allow the presented system to perform its functions with unique versatility and efficiency, without the already mentioned inconveniences. This patent application presents a practical and innovative automated manufacturing process with all practical and functional qualities, projected and developed according to the most up-to- date skills, therefore enabling its most varied uses, since the industrial use in the manufacture of electronic components such as transponders, up to its use in the manufacture of small magnetic coils for generic use, as well as in industrial use in various cases. Its innovative production equipment allows to reach an excellent functionality level, offering an automated manufacturing system with large enduringness, having been mainly created to substitute manual procedures and machines with high acquisition cost. The configuration of the automated industrial procedure object of this patent, in its new constructive form, comprises a sole equipment or a series of interconnected equipments to automatically execute the tasks which were usually divided between machines and specialized human beings. It should therefore be realized that the automatic process at issue has been created in an extremely simple way, being therefore easily feasible, but excellent practical and functional results are obtained, thus offering innovative construction over the known models. Built with an innovative design, it results in a harmonic set with very peculiar and especially characteristic aspect and, besides the building aspect, the model is highlighted by its versatility and handy use. For a better understanding and realization of what constitutes the PROCESS TO MANUFACTURE TRANSPONDER AND THE CORRESPONDING PRODUCTION EQUIPMENT as claimed herein, we present below the attached illustrative drawings, which show: Fig. 1 shows a side perspective view of the equipment executing the whole manufacturing process of the electronic component like a transponder. Fig. 2 shows a partial perspective view of the equipment as mentioned, highlighting the central rotating table. Fig. 3 shows a perspective view of the chip feeding system in the body of the equipment. Fig. 4 shows a perspective view of a robot arm taking a chip from its commercialization strip by means of the suction system. Fig. 5 shows a perspective view of the arm moving the chip up to its fixing platform. Fig. 6 shows a perspective view of the robot arm laying the chip on the fixing platform. Fig. 7 shows an upper view of the chip laid over the fixing platform, still in an inadequate position. Fig. 8 shows an upper view of the fixing table, by using the sliding blade in perpendicular angle to automatically ordinate the position of the chip and fixing it for the rest of the process. Fig. 9 shows an upper view of the pressing head with the sliding blade in the withdrawn position. Fig. 10 shows an upper view of the pressing head with the sliding blade in the extended position. Fig. 11 shows a perspective view of the coiling equipment of the wire being automatically put into action. Fig. 12 shows a perspective view of the coiling equipment passing the wire through the sides of the moving wings. Fig. 13 shows a perspective view of the coiling equipment starting to roll up the wire in the special magnetic tool or magnetic mold. Fig. 14 shows a perspective view of the coiling equipment finishing to roll up the wire in the magnetic mold. Fig. 15 shows a perspective view of the coiling equipment passing the wire through the opposed sides of the moving wings. Fig. 16 shows a side perspective view of the circular rotating table at the end of coiling. Fig. 17 shows an end perspective view of the circular rotating table at the end of coiling. Fig. 18 shows a perspective view of the rotating table being displaced to position the fixing platform under the soldering tool. Fig. 19 shows a perspective view of the soldering tool with all its support structure. Fig. 20 shows a perspective view of the soldering tool starting to slope towards its end part, thus providing for perfect positioning of the pressing edge. Fig. 21 shows a perspective view of the soldering tool with advanced regulation. Fig. 22 shows a perspective view of the soldering tool performing a rotating movement to the right. Fig. 23 shows a perspective view of the soldering tool performing the rotating movement to the left. Fig. 24 shows a perspective view of the fixing platform under the soldering tool. Fig. 25 shows a perspective view of the soldering tool fixing the wires by mechanical pressure exerted over them against chip contacts, while the end mobile wing is moved behind, breaking the wires in the exact point of the solder. Fig. 26 shows a perspective view of the soldering tool being concealed. Fig. 27 shows a side perspective view of the coiled magnetic tool with the wire and already with the chip soldered at its ends. Fig. 28 shows a perspective view of the rotating table being displaced up to a frontal position with the vertical rotating table. Fig. 29 shows a perspective view of the transposition of the magnetic tool of the horizontal rotating table to the vertical table. Fig. 30 shows a perspective view of the vertical rotating table, by dipping the chip into a container with a protecting waterproofing liquid similar to a fluid polymeric resin. Fig. 31 shows a perspective view of the transposition of the magnetic tool to another horizontal rotating table provided with a heating and drying system for the polymeric resin by means of ultraviolet rays. Fig. 32 shows a perspective view of the magnetic tool being disassembled and releasing the transponder as already assembled inside it. According to the illustrations in the above listed figures, the PROCESS TO MANUFACTURE TRANSPONDER AND THE CORRESPONDING PRODUCTION EQUIPMENT object of this patent is essentially characterized by being constituted of a manufacturing process using an equipment constituted by a set of supports (1) for the reel (2) of the plastic band (3) on which chips (4) used herein are commercialized and make them available for handling by a robot arm (5) transporting them by suction up to the main horizontal rotating table (6). The four fixing tables (7) using perpendicularly angled sliding blades (8) to automatically ordinate the position of the chip (4) and immobilize them during the rest of the process. Said perpendicularly angled blades (8) perform the function of a square, since they have the frontal portion provided with a 90° cutting, while the seating basis of the chip has a square format. Therefore, the chip may be put in any position within the seating basis and the blades while moving will carry and position the chip in the right position for both linking contacts to be aligned within the exact position for wire soldering. This point is extremely important and decisive for the rest of the process, due to the miniaturized size of the chip and reduced thickness of wires soldered therein. After putting and ordinating the chip (4) on the fixing platform (7), the main horizontal rotating table (6) performs 45° rotation, stopping in front of the coiling equipment. Said equipment is composed by a coil support (9), a tensioning and aligning guide (10), a rotation motor (11) of the system and a curved needle (12) inside which the enameled metal wire passes. The coiling of the wire as made by the needle (12) as described above is made around a magnetic metal tool or magnetic mold (13) composed by two segments fitted in by prominences and recesses, joined by the magnetic force existing between both. The magnetic tool (13), on the other hand, is also fixed to the side of the main horizontal rotating table (6) by means of the magnetic force exerted by it against the table metal. The side of the table has at this point a series of different holes, so to enable a wide range of magnetic tools which will be appropriate for the manufacture of various kinds of products of this kind. However, no matter which is the used tool, the general features remain unchanged, be them while coiling or while positioning the wires with relation to the perpendicularly angled blades (8). Such positioning or "twisting" is automatically performed by the rotation movement of the table simultaneously with the advance and return of the coiling block. Wire interlacing around the perpendicularly angled blades (8) is basic in two main aspects as follows: the correct positioning of the wires over the electrical contacts of the chip and the function of breaking the wires exactly when the pressure is exerted by the soldering tool, considering the function of separation caused by an articulation commanded by a solenoid positioned at the lower portion of the rotating table. After correctly coiling the magnetic tool (6) and the passage of wires around the mobile wings (14) existent on the fixing platform (7) of the chip, the main horizontal rotating table (6) rotates 45° more until stopping under the soldering tool. Mobile wings also perform a decisive function in the perfect operation of the process described herein, for the following reasons: due to the measurements of just a few micra of the chip and the wires which should be soldered therein, it has always been extremely difficult for an automated process with simple features to be able to reach the required precision to position both wires exactly over the contacts of the chip. Mobile wings perform, among others, the main purpose to serve as an obstacle with precise thickness for tensioned wires to be abutted around them. Therefore, positioning of wires with great precision becomes extremely simple, i. e. it is enough that the wires are tensioned in contact with both side faces of the wing, since it has exactly the same thickness of the one separating both electrical contacts in the chip. The soldering tool constitutes a diamond punch (15) exerting pressure over the wires positioned exactly above the electrical contacts of the chip (4). The soldering tool is extremely important in the presented process, since it enables perfect adjustment and positioning of the diamond punch exerting the required pressure to press and melt extremely thin wires in their respective electrical contacts of the chip. The end of the diamond punch as a "V" format with one of its sides slightly curved or bulged, so to cause smashing and melting of the wires at their respective contacts of the chip. The other side of the diamond punch has acute angles and therefore favors the cutting and breakage of wires. For this reason, the exact positioning and slope of the diamond punch is basic and fundamental, since, if the punch has incorrect slope or position, wires will not be smashed at the right point of the metal contacts of the chip and there will also not be the point of cutting or breaking the wires at the exact point, and they can even become loose, compromising the operation of the product being manufactured. To enable slope and positioning adjustment in such a way that the diamond punch does not loose the contact center and needs many hours for a new adjustment, a translational rotation system allowing 360° adjustment not moving the edge ahead or behind, to the left or to the right, with the adjustment concentrating solely in the slope angle. By means of pressure, the wire melts to the contacts and in that precise moment the end mobile wing (14) is moved behind with the help of a lower solenoid, breaking the wires and releasing the continuity of the process. After this stage, the main horizontal rotating table (6) rotates 45° more, positioning itself in front of the secondary vertical rotating table (16). The secondary vertical rotating table (16) magnetically catches from the horizontal table (6) the tool (16) which contains inside it the coil already with the welded chip, dipping it in a fluidified polymeric solution (17), such as a photopolymerizable resin. Again, the magnetic tool (13) is caught by a tertiary horizontal rotating table (18) having a solidary partial protecting cover (19) inside which a heating oven and a source of ultraviolet rays are located to provide for the photopolymerization of the encapsulating resin (17) of the chip (4). Said tertiary horizontal rotating table (18) moves in a circle up to the position where a robot arm (20) disassembles or disconnects both halves of the magnetic tool (13), thus releasing the transponder contained inside it, again putting the portion of tool taken into its place of origin, re-starting the return process of the empty tool up to the main horizontal rotating table (6). The present description therefore dealt with a new conception in automated manufacturing of electronic components of the mentioned type, presenting, as we were able to show by the effected analysis and the shown figures, numerous differences between conventional procedures and machineries existing in the consumer market, besides fully different constructive and functional technical features from those pertaining to the state of the art. For the offered advantages and also for having truly innovative features fulfilling all the requirements of novelty and originality in the field, the present PROCESS TO MANUFACTURE TRANSPONDER AND THE CORRESPONDING PRODUCTION EQUIPMENT gathers the required conditions to deserve the Privilege of Invention.

Claims

CLAIMS 1. PROCESS TO MANUFACTURE TRANSPONDER AND THE CORRESPONDING PRODUCTION EQUIPMENT essentially characterized by being constituted by a manufacturing process using an equipment constituted by a set of supports (1) for the reel (2) of the plastic band (3) on which chips (4) used herein are commercialized and make them available for handling by a robot arm (5) transporting them by suction up to the main horizontal rotating table (6); on that table, the four fixing tables (7) are located, which use perpendicularly angled sliding blades (8) to automatically ordinate the position of the chip (4) and immobilize them during the rest of the process; after putting and ordinating the chip (4) in the fixing platform (7), the main horizontal rotating table (6) performs 45° rotation, stopping in front of the coiling equipment; said equipment is composed by a coil support (9), a tensioning and aligning guide (10), a rotation motor (11) of the system and a curved needle (12) inside which the enameled metal wire passes; the coiling of the wire as made by the needle (12) as described above is made around a magnetic metal tool or magnetic mold (13) composed by two segments fitted in by prominences and recesses, joined by the magnetic force existing between both; the magnetic tool (13), on the other hand, is also fixed to the side of the main horizontal rotating table (6) by means of the magnetic force exerted by it against the table metal; after the correct coiling of the magnetic tool (6) and the passage of the wires around the mobile wings (14) existing on the fixing platform (7) of the chip, the main horizontal rotating table (6) rotates 45° more until stopping under the soldering tool, which constitutes a diamond punch (15) exerting pressure over the wires positioned exactly above the electrical contacts of the chip (4); by means of pressure, the wire melts to the contacts and, exactly then, the end mobile wing (14) moves behind with the help of a lower solenoid, breaking the wires and releasing the continuity of the process; after this stage, the main horizontal rotating table (6) rotates 45° more, positioning itself in front to the secondary vertical rotating table (16); the secondary vertical rotating table (16) magnetically catches from the horizontal table (6) the tool (13) containing inside it the coil already with the soldered chip, by dipping it into a fluidified polymeric solution (17), such as a photopolymerizable resin; again, the magnetic tool (13) is caught by a tertiary horizontal rotating table (18) having a solidary partial protective cover (19) inside which a heating oven and a source of ultraviolet rays are located to provide for the photopolymerization of the encapsulating resin (17) of the chip (4); said tertiary horizontal rotating table (18) moves in circles up to the position in which a robot arm (20) disassembles or disconnects both halves of the magnetic tool (13), releasing the transponder contained inside it, again putting the portion of the tool taken into its place of origin, restarting the return process of the empty tool up to the main horizontal rotating table (6).