Miniature Chip Card Detachment via Segmented Web Connections
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Solution Overview
Problem
Existing chip card production methods require high forces to detach miniature chip cards, leading to potential destruction and delamination, especially with the ongoing miniaturization of mobile radio terminals, which demands smaller dimensions and thinner profiles for SIM cards, increasing the risk of mechanical stress and malfunction.
Innovation Solution
A chip card design featuring a card body with full-circumferential gaps along the outer contour of the miniature chip card, held by two connections on the side edges, where the connections are shaped as ridges with a width corresponding to half the side edge length, allowing for easy detachment with an ejection force of less than 20 Newtons, and strategically positioned webs to minimize mechanical stress during separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high forces are applied to detach miniature chip cards from card bodies using conventional methods (laser perforation, multiple cutting lines), then the miniature chip card can be removed from the card body, but the mechanical stress causes destruction, delamination of the chip module, or breaking of parts
Solution Approach 1:
The card body is segmented into a main body and a detachable miniature chip card portion through a discontinuous outer contour gap. This gap is interrupted by connecting bridges that provide controlled attachment points, allowing the miniature chip card to be separated from the card body by applying force only at specific locations rather than across the entire structure, thereby reducing mechanical stress and preventing destruction
Solution Approach 2:
The connecting bridges are designed with specific local properties: they have optimized widths (5-15 mm) and are positioned at predetermined locations on the outer contour. The bridges create localized stress concentration points that guide the detachment process, ensuring that mechanical stress is applied only at these specific locations rather than distributed across the entire chip card structure, thus preventing delamination and breaking
2Volume of moving object
If the dimensions of miniature chip cards are reduced to meet miniaturization demands (smaller than 3FF format), then mobile radio terminals can be further miniaturized, but the residual wall thickness decreases making the chip card more susceptible to destruction during detachment
Solution Approach 1:
The card body is pre-configured with discontinuous outer contour gaps and strategically positioned connecting bridges before the miniature chip card needs to be detached. This preliminary structural arrangement ensures that when detachment is required, the mechanical stress is automatically directed to the predetermined bridge locations rather than random areas, preventing destruction even in miniaturized cards with thin residual wall thickness
Solution Approach 2:
The connecting bridges are designed with optimized dimensional parameters (width of 5-15 mm, specific positions on the outer contour) that balance the conflicting requirements of providing sufficient holding force during production while enabling easy detachment with minimal stress. These parameter optimizations allow miniaturized chip cards to maintain adequate mechanical strength despite reduced overall dimensions and thinner residual wall thickness
3Ease of operation
If conventional detachment methods (laser perforation, multiple cutting lines) are used, then the miniature chip card can be separated from the card body, but the manufacturing process becomes complex and production time increases
Solution Approach 1:
The detachment function is extracted from complex manufacturing processes (laser perforation, multiple cutting operations) and embedded directly into the card body structure through the discontinuous outer contour gap and connecting bridges. This structural extraction allows detachment to be achieved by simple mechanical force application at predetermined locations, eliminating the need for complex manufacturing steps while maintaining ease of operation
Solution Approach 2:
The card body is pre-formed with discontinuous outer contour gaps and connecting bridges during the manufacturing process, so that when the miniature chip card needs to be detached, the structural preparation is already complete. This preliminary structural configuration simplifies the detachment operation to a single force application step, reducing manufacturing complexity and production time compared to methods requiring multiple cutting or perforation operations
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The invention relates to a chip card with a card body (1), wherein a miniature chip card (4) can be detached from the card body (1); an integrated semiconductor circuit (81) is inserted in the miniature chip card; the card body (1) has, along the outer contour of the miniature chip card (4), a complete gap (7), apart from two connections, by means of which the miniature chip card (4) is held in the card body (1), and the two connections (6) are arranged on in each case one side edge of the outer contour of the miniature chip card (4). In this case, both connections (6) are in the form of webs (5).