Method for application of a chip module to an antenna

A method for application of a chip module to an antenna module includes supplying a plurality of chip modules arranged in a row arrangement on a sheet carrier. Separating chip modules from the row arrangement and transferring the separated chip modules to a application device. The chip module separated from the row arrangement are subsequently positioned on the antenna substrate by the application device and contacting of the antenna contact surfaces of the chip module with the contact surfaces of the antenna is performed. The invention further relates to a device for the application of a chip module to an antenna module.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the priority benefit to PCT International Application No. PCT/EP2009/002067 filed on Mar. 20, 2009, which claims priority to German Patent Application No. 10 2008 016 830.0 filed on Mar. 28, 2008, both of which are fully incorporated herein by reference.

Not applicable.

FIELD OF THE INVENTION

The present invention relates to a method for application of a chip module on an antenna module, wherein antenna contact surfaces formed on an application side of the chip module are contacted with contact surfaces of an antenna disposed on an antenna side of an antenna substrate in an electrically conductive manner, wherein a plurality of chip modules are arranged in a row arrangement on a sheet carrier and the row arrangement is supplied to a separating device arranged at the application location by means of a supply device, the chip module separated from the row is subsequently positioned on the antenna substrate by means of an application device and contacting of the antenna contact surfaces of the chip module with the contact surfaces of the antenna is performed.

BACKGROUND OF THE INVENTION

During large-scale production of so-called transponder modules, antenna modules which each feature an antenna furnished with terminal contacts and disposed on an antenna substrate are conveyed past an assembly station in a matrix arrangement, in which the individual antennas are contacted with chip modules. In particular as a result of the large web widths of the antenna module webs, which are meanwhile common practice due to the matrix arrangement, equipment of the antennas with the chip modules requires the passage of sometimes extensive manipulation zones via which the chip modules need to be separately guided until contacting on the antenna substrates is realized. In this process, the supply of the chip modules is regularly performed transversely to the conveying direction of the antenna substrate web. Apart from the temporal expenditure involved in supplying the chip modules it has proven disadvantageous that the supply of the separated chips necessitates the installation of transport devices of correspondingly complex design.

SUMMARY OF THE INVENTION

Thus, it is an object of the present invention to make it possible to perform the supply of chip modules for subsequent contacting with the antenna modules more efficiently, namely in particular more rapidly and subject to comparatively reduced mechanical complexity.

This object is attained by a method in which, a plurality of chip modules disposed in a row arrangement on a sheet carrier are supplied to a separating device arranged at the application location. By means of this measure, the logistical and mechanical complexity involved in the handling and conveyance of chip modules, which have already been separated beforehand and which need to be separately transferred to the application location, can be dispensed with. Instead, according to the invention, the row arrangement per se, i.e. a simple forward movement of the row arrangement, is utilized for conveying the chip modules arranged in the row assembly to the application location and for separating the chip modules from the row assembly only at the location where the application is performed, for positioning the chip modules on the antenna substrate by means of the application device and for contacting the chip modules with the antenna.

According to the invention, the separation of the chip module is thus only performed in the region of the application device, so that the sheet carrier arrangement per se can be advantageously utilized for conveyance up to the application device.

The efficiency of the inventive method can be further enhanced if the sheet carrier features a plurality of row arrangements which extend in parallel to one another into the longitudinal direction of the sheet carrier and which are separated at a distance from the application location in order to be supplied to the separating device at the application location in the form of individual rows.

In this process, the separation of the row arrangements from the sheet carrier can be performed while the row arrangements are supplied to the separating device or else can be performed independently thereof, wherein concerning the latter case, the row arrangements separated from the sheet carrier can be arranged on a storage device in the form of a rolled-up storage roll and can be supplied to the separating device only subsequently starting from the storage device.

It is particularly advantageous in terms of a mechanically resistant and sealing connection of the chip module with the antenna module if subsequent to the positioning and preceding the contacting an adhesively bonded connection is established between the chip module and the antenna substrate in a contact region surrounding a chip and the antenna contact surfaces.

In contrast hereto, it is also possible that the adhesively bonded connection is established subsequent to contacting.

According to a particularly preferred method variant, for performing the separation, the row arrangement of the chip modules is guided out of a supply channel until a rear longitudinal end of the foremost chip module in the supply channel is brought into contact with a first fixed cutting edge of the separating device, which defines the end of the supply channel. Subsequently, a cutting arm comprising a second cutting edge is swiveled past the fixed cutting edge for isolating, respectively separating the foremost chip module from the row arrangement. The method thus makes it possible to utilize a device that can be accommodated in an extremely confined space and that utilizes the cutting movement simultaneously for transfer of the cut-off, respectively separated chip module to the application device.

In order to be able to maintain a defined spatial alignment of the chip modules already during supply of the chip modules in a row arrangement and to be able to largely preclude positional changes of the chip module due to the cutting movement, it is advantageous if the foremost chip module is retained on an abutment surface of the cutting arm while being separated from the row arrangement and while being transferred to the application device. At the same time, it is hence ensured that the separated chip module is placed in a defined position during transfer to the application device.

A particularly efficient configuration requiring reduced mechanical complexity to achieve a retaining function can be realized if the chip module is retained against the abutment surface by means of the application of underpressure.

In order to be able to ensure a defined and reproducible positioning of the chip module also subsequent to the transfer to the application device, it is advantageous if the cutting arm is swiveled with its abutment surface against an abutment surface of the application device for transferring the chip module to the application device in such a manner that the application of underpressure at the cutting arm is maintained until abutment against the abutment surface of the application device is realized and underpressure is subsequently applied to the chip module via the abutment surface of the application device.

An application being performed as directly as possible subsequent to the transfer of the chip module to the application device is enabled if the application device comprising the chip module retained on the abutment surface is moved towards the antenna substrate for performing positioning with subsequent contacting and is exposed to ultrasonic vibrations while abutting against the antenna substrate.

An advantageous adaptation of the method to the respective width of the antenna module web, respectively to the number of the antenna modules arranged along the width of the antenna module web, is rendered possible if for supplying, separating and applying the chip modules, a plurality of antenna modules disposed in a matrix arrangement are assigned a number of row arrangements of the chip modules of the matrix arrangement, said number corresponding to the number of row arrangements of the matrix arrangement which are advanced into the feeding direction, in such a manner that the row arrangements are advanced into the same direction as the assigned rows of the matrix arrangement.

The method can be performed in a particularly simple and space-saving manner in antenna modules disposed in a matrix arrangement if the supplying devices, separating devices and application devices assigned to each row of the matrix arrangement are accommodated in a stationary portal arrangement and if the antenna modules disposed in the matrix arrangement are passed through underneath the portal arrangement in a clocked manner.

To attain this object, the inventive device features a supply device for supplying a plurality of chip modules disposed in a row arrangement on a sheet carrier, a separating device for separating the chip modules from the row arrangement and transferring the separated chip module to an application device, wherein the application device serves for positioning the chip module on an antenna substrate of the antenna module and contacting of the antenna contact surfaces of the chip module with the contact surfaces of the antenna.

According to a preferred embodiment, the device has a separating device that features a supply channel comprising a cutting edge formed at the frontal end in the feeding direction and a cutting arm being swivelable with respect to the supply channel and comprising a second cutting edge which can be moved past the first cutting edge.

It is particularly advantageous if the cutting arm is furnished with an abutment surface for accommodating the chip module and which is equipped with a retainer device for fixing the chip module to the abutment surface.

The retainer device is preferably formed as an underpressure device which is arranged in the abutment surface.

A particularly space-saving and functionally integrated configuration of the device is enabled if the cutting arm, with the abutment surface thereof, is swivelable against an abutment surface of the application device and if the abutment surface of the application device is equipped with an underpressure device for taking over the chip module from the abutment surface of the cutting arm.

For performing the application directly subsequent to taking over the chip module from the separating device, the application device features a feeding device for moving the chip module arranged on the abutment surface against the antenna substrate and an ultrasonic device for exposing the chip module arranged on the abutment surface to ultrasonic vibrations.

A particularly compact configuration of the device is enabled if the supply device, the separating device and the application device form an application module that is arranged on a common carrier frame.

A substantially autarkic operation of the device being essentially independent of the storage devices arranged at the outside of the antenna substrate web can be realized if the application module is equipped with a storage device for arrangement of an endless sheet carrier in the form of a roll.

A particularly simple and fast adaptation of the device to varying web widths of the antenna module web or varying numbers of rows of antenna modules formed in the antenna module web is realizable if the application modules can be combined in any optional number for forming an application unit.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIG. 1shows a sheet carrier20that comprises chip modules27which are each arranged in a row arrangement21,22,23,24,25and26in longitudinal alignment one behind the other. The chip modules27are each arranged in the row arrangements21to26in such a manner that the longitudinal ends28,29of adjacent chip modules27directly adjoin one another.

As shown inFIGS. 2 and 3, each individual chip module27comprises a carrier substrate30which is formed from the material of the sheet carrier20and which has two terminal conductors31,32formed thereon, which, in a center region thereof, have a contact surface arrangement33for contacting a chip and which, in the region of the longitudinal ends28,29of the chip module27, each have an antenna contact surface34and35, serving for establishing an electrical contact with an antenna module37, for instance illustrated inFIG. 4. With the exception of the contact surface arrangement33and the antenna contact surfaces34,35, in the exemplary embodiment illustrated inFIG. 2, an application surface36, by means of which the chip module27is connected to the antenna module37illustrated inFIG. 3, is furnished with a coating layer made of an adhesive material38.

FIG. 4schematically illustrates a method variant in which the row arrangements98,99,100are separated by means of a separating device, here designed in the form of a cutting device101, from a sheet carrier97, which comprises a plurality of row arrangements98to100of chip modules27disposed in parallel to one another and extending in the longitudinal direction of the sheet carrier, at a distance from the antenna modules37arranged in a matrix arrangement42or a matrix assembly. During separation, the row arrangements98,99,100are further transferred to the respective application locations102,103,104, where the chip modules27are contacted with the antenna modules37. Thus, the separation of the row arrangements98,99,100and the supply of the row arrangements to the application locations102,103,104are performed “in line”.

FIG. 5schematically illustrates a method variant in which the row arrangements98to100are separated independently of the supply and of the subsequent contacting of the chip modules firstly by means of the cutting device101and are then each rolled up to form a storage roll105. The storage rolls105can then be arranged on storage devices58in relative proximity to the application locations102,103,104. Starting from the storage devices58, the row arrangements98,99,100are then supplied to the respective application locations102,103,104, where the chip modules27are separated from the row arrangements98,99,100and are contacted with the antenna modules37.

FIG. 6, as already mentioned above, shows a chip module27which is applied to the antenna module37, i.e. in such a manner that a chip96arranged on the carrier substrate30or contacted with the contact surface arrangement33is contacted in an electrically conductive manner with contact surfaces40,41of an antenna39via the antenna contact surfaces34,35illustrated inFIG. 6using dash-dotted lines, the antenna contact surfaces being formed on an antenna substrate49of the antenna module37.

As is also evident fromFIG. 6, for application of the chip module27to the antenna module37, the row arrangements21to26of the chip module27assigned to the chip module37are aligned beforehand, as can be seen from the overall view ofFIG. 7. Prior to the application of the chip modules27which are intended for connection with the individual antenna modules37, assignment of the row arrangements21to26is performed, the number of row arrangements corresponding to the rows43to48of the antenna modules37formed in a matrix arrangement42of the antenna modules37. In this process, the row arrangements21to26of the chip modules27are each located in a flush arrangement with the contact surfaces40,41of the antennas39formed on the antenna modules37.

As is apparent from the schematic representation according toFIG. 7, it is basically possible, in case of a separation of the row arrangements21to26differing from the illustration ofFIG. 1, to arrange the individual chip modules27of the row arrangements21to26at a distance from one another, corresponding to the distance between the contact surfaces40or41of adjacent chip modules, such that the contacting of a plurality of chip modules27of a row arrangement21to26with the antenna modules37arranged in a row43to48could be simultaneously performed.

To this end, the matrix arrangement42of the antenna modules37and the row arrangements21to26of the chip modules27would be synchronously advanced into the production direction50. Alternatively, however, as illustrated in FIG.14, it is also possible to make provision for fixed application modules52to57which are for instance arranged in a common portal arrangement51and which are assigned to the individual row arrangements43to48of the antenna modules37arranged in the matrix arrangement42on the antenna module carrier49. In this process, the individual rows43to48of the antenna modules37are passed through underneath the portal arrangement51into the production direction.

FIG. 8shows an application module52in an isolated view comprising the functional devices formed thereon, each comprising a storage device58, a supply device59, a separating device60and an application device61. The storage device58serves for accommodating a row arrangement21to26of the chip modules27in a roll format. By means of the supply device59, which in the present case is composed of a driving roll unit, the row arrangement is conveyed through a supply channel62which is furnished with a cutting edge65in the region of the outlet orifice63at a channel wall64thereof. A cutting arm66which is swivelably connected to the supply channel62is equally disposed in the region of the outlet orifice63and is likewise furnished with a cutting edge67which, on a swivel arc70, is moved past the cutting edge65about a swivel axis68formed at the supply channel62when the cutting arm66performs a swiveling motion.

The application device, which features an ultrasonic plunger72, is located adjacent to the supply channel62and with the adjustment axis69thereof intersects the swivel arc70, whereby ultrasonic vibrations are transferred to the ultrasonic plunger72via an ultrasonic converter73.

Hereinafter, the function of the application module52will be described in more detail with reference toFIGS. 10A to 10C.

As is apparent from the illustration according toFIG. 10A, the row arrangement21is advanced through the supply channel62by means of the supply device59until the foremost chip module27in the row arrangement21, with the rear longitudinal end28thereof, is arranged in the region of the cutting edge65. In this relative arrangement, the chip module27extends over an abutment surface74formed on the cutting arm66. When the chip module27has reached the position illustrated inFIG. 10Aon the abutment surface74of the cutting arm66, underpressure is applied to the abutment surface74by means of an underpressure device (not illustrated here in greater detail), said underpressure fixing the chip module27on the abutment surface74.

Starting from the configuration illustrated inFIG. 10A, according to the representation illustrated inFIG. 10B, swiveling of the cutting arm66about the swivel axis68is performed in such a manner that the abutment surface74comprising the chip module27arranged thereon describes the swivel arc70, wherein the cutting edge67formed at the abutment surface74is moved past the fixed cutting edge65resulting in that the chip module27, in the region of the rear longitudinal end28thereof, is isolated from the row arrangement21.

Simultaneously with the movement performed on the swivel arc70to perform isolation, as can be seen fromFIG. 10B, the chip module27arranged on the abutment surface74is moved against an abutment surface75formed at the ultrasonic plunger72.

As is evident fromFIG. 10B, the abutment surface75, at the rear side thereof, is equipped with an underpressure device76that is provided with an underpressure terminal77for connection to an underpressure source (not illustrated here in greater detail). For transferring the chip module27from the abutment surface74of the cutting arm66to the abutment surface75of the ultrasonic plunger72, the application of underpressure to the abutment surface75is activated and the application of underpressure to the abutment surface74is deactivated. After deactivation of the application of underpressure to the abutment surface74, as illustrated inFIG. 10C, a backward movement of the cutting arm66on the swivel arc70is performed until the initial position of the cutting arm66illustrated inFIG. 10Ais reached, in which initial position the subsequent chip module27in the row arrangement can be positioned on the abutment surface74by means of another feeding movement of the row arrangement21.

Simultaneously with or subsequent to the backward movement of the cutting arm66on the swivel arc70, a vertical feeding movement of the ultrasonic plunger72is performed longitudinally along the feed axis69in such a manner that the chip module27fixed at the abutment surface75is moved against the antenna substrate78via the application of underpressure75, as shown inFIG. 11. In this process, the antenna contact surfaces34,35of the chip module27are caused to overlap with the contact surfaces40,41of the antenna39. By means of exposing the ultrasonic plunger to ultrasonic vibrations, an electrically conductive welding contact is finally established between the antenna contact surfaces34,35and the contact surfaces40,41of the antenna39. The production of the welding connection is particularly efficient with the aid of ultrasound technology if both the antenna contact surfaces34,35and the contact surfaces40,41are composed of aluminum.

As can be seen in particular fromFIG. 14, in addition to the portal arrangement51comprising the plurality of application modules52to57formed thereon, provision is made for another portal arrangement79that exhibits a plurality of sealing modules80to85. The sealing modules80to85are correspondingly assigned to the application modules52to57in terms of their assignment to the individual row arrangements43to48of the antenna modules37. In contrast to the application modules52to57, the sealing modules80to85are placed closer at the front in the production direction50and, subsequent to the preceding electrical contacting of the antenna contact surfaces34,35of the chip module27with the contact surfaces40,41of the antennas39of the antenna modules37, serve for producing the sealing between the chip module27, respectively the carrier substrate30of the chip module27, and the antenna substrate49of the antenna module37.

FIG. 9shows a sealing module80comprising an ultrasonic plunger86to which ultrasonic vibrations can be applied using an ultrasonic converter87. Moreover, the ultrasonic plunger86is furnished with a feeding device88that makes it possible to feed the ultrasonic plunger86into the direction of a feed axis89.

As can be seen from a combined view ofFIGS. 9 and 12, the ultrasonic plunger86is furnished with an indentation profile91that forms a peripheral contact frame93in the region of an abutment surface92against a back side of the carrier substrate30, the contact frame having dimensions and a profile width configured such that a contact region94with the carrier substrate30illustrated in a hatched manner inFIG. 13is realized. Due to the application of ultrasound to the carrier substrate30, a solid and mechanically resistant connection is produced in the contact region94between the adhesive material38, which is preferably formed as a contact adhesive and is applied to the application surface36of the chip module27(FIG. 2andFIG. 3), and the antenna substrate49of the antenna module37. Due to the insulating effect produced by the adhesive material38, the adhesively bonded contact producing a hermetic seal and a mechanically resistant connection can be established both between the adhesive material38and the substrate material of the antenna substrate49as well as between the adhesive material38and regions of windings95of the antenna39that are bridged via the chip module27.