Angled Antenna Ends for Smart Card Manufacturing
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Solution Overview
Problem
The existing manufacturing process for electronic documents, such as smart cards, often results in antenna wire ends being dislodged during machining, leading to potential short circuits and reduced contact zones, compromising the functionality of the card.
Innovation Solution
The antenna ends are arranged in a zigzag shape with rectilinear portions inclined relative to the cutting plane, ensuring better retention and a larger connection surface, using a conductive anisotropic adhesive for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the antenna wire ends are positioned to extend to the upper edge of the lower counterbore to maximize connection area, then the connection area is maximized, but the wire becomes dislodged during machining
Solution Approach 1:
The patent applies asymmetry by positioning the antenna wire ends at an angle relative to the horizontal machining plane, rather than parallel to it. This asymmetric orientation ensures that the wire ends do not lie flat against the upper edge of the lower counterbore, preventing dislodgment during machining while still maximizing the connection area available for electrical contact.
Solution Approach 2:
The patent introduces a dimensional change by tilting the antenna wire ends out of the horizontal plane. Instead of extending purely in the horizontal direction parallel to the machining plane, the wire ends are oriented at an angle, adding a vertical component to their positioning. This dimensional adjustment allows the wire ends to maintain optimal connection area while avoiding the dislodgment issue caused by horizontal positioning at the counterbore edge.
2Ease of manufacture
If the antenna wire ends are positioned parallel to the machining plane to facilitate machining, then machining is simplified, but the wire ends are dislodged and create short circuit risks
Solution Approach 1:
The patent resolves this contradiction by采用不对称布局，使天线线端与机械加工平面成角度，而非平行。这种不对称设计在保持加工可行性的同时，有效防止了线端在加工过程中被 displacement 的风险，从而消除了短路隐患。
Solution Approach 2:
The patent applies preliminary anti-action by pre-positioning the antenna wire ends at an angled orientation before the final machining steps. This preliminary positioning ensures that during the machining process, the wire ends are not susceptible to dislodgment forces, thereby preventing the harmful effect of short circuits before they can occur.
3Area of stationary object
If the antenna wire ends are positioned tangent to the upper edge of the lower counterbore, then the connection area is maximized, but the wire is no longer properly held after machining
Solution Approach 1:
The patent resolves this contradiction by positioning the antenna wire ends asymmetrically at an angle to the horizontal machining plane, rather than tangentially parallel to it. This asymmetric positioning allows the wire ends to extend to the upper edge of the lower counterbore for maximum connection area while maintaining stability by not lying flat against the edge where they would be dislodged during machining.
Solution Approach 2:
The patent introduces a vertical dimension to the wire end positioning by tilting them at an angle relative to the horizontal plane. This dimensional change allows the wire ends to achieve maximum horizontal extension for connection area while the vertical angle component provides mechanical stability, preventing dislodgment during the machining process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This arrangement prevents wire dislodgment and ensures reliable electrical connections, reducing the risk of short circuits and maintaining optimal contact zones for efficient card operation.
Implementation Method 1
using a conductive anisotropic adhesive for secure electrical connections
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to an electronic document comprising a body (12) including a cavity (24) open on one the surfaces of the body (12) and defined by walls, said body (12) further comprising an antenna (36) which comprises at least one turn (36c) extending between two ends (36a, 36b) that lead to a wall of the cavity (24), a module (14) comprising a microprocessor (16) and at least two connection terminals (20a, 20b) for the antenna (36) and connected electronically to the microprocessor (16) and to the ends (36a, 36b) of the antenna (36) via electrical connection means. The ends (36a, 36b) of the antenna are arranged in a zigzag pattern and are composed of at least two straight portions (42) connected to each other by a bend (44), the straight portion (42) which leads to the cavity being angled relative to the wall at which it terminates.