Abstract:
In an embodiment of the present invention, a single-sided memory card includes a single-sided memory card includes an injection- or transfer-molded base including the cavity, a thermal adhesive glue sheet position in the cavity, a PCBA secured inside the cavity of the single-sided memory card through the thermal adhesive glue sheet, and an adhesive label position on top of the PCBA, causing the PCBA to be protected and, after heating, the adhesive is cured binding the injection- or transfer-molded base.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of copending U.S. patent application Ser. No. 10/913,868 entitled “Removable Flash Integrated Memory Module Card and Method of Manufacture”, filed Aug. 6, 2004, and is a continuation-in-part of copending U.S. patent application Ser. No. 11/773,830, entitled “Molding Method to Manufacture Single-Chip Chip-On-Board USB Device”, filed on Jul. 5, 2007, and is a continuation-in-part of copending U.S. patent application Ser. No. 11/309,847 entitled “USB Device with Integrated USB Plug with USB-substrate Supporter Inside” and filed on Oct. 12, 2006 and is a continuation-in-part of U.S. patent application Ser. No. 11/624,667, entitled “Electronic Data Storage Medium with Fingerprint Verification Capability”, filed on Jan. 18, 2007 which is a divisional application of U.S. patent application Ser. No. 09/478,720, entitled “Electronic Data Storage Medium with Fingerprint Verification Capability” and filed on Jan. 6, 2000. 
         [0002]    This application is related to U.S. Pat. No. 7,094,074, entitled “Manufacturing Methods for Ultra-Slim USB Flash-Memory Card with Supporting Dividers or Underside Ribs”, filed on Oct. 28, 2004. 
     
    
     BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    The present invention relates generally to the field of removeably connectable memory cards (or devices) and particularly to card-based devices such as secure digital (SD) memory cards, mini-SD memory cards, and micro-SD memory cards. 
         [0005]    2. Description of the Prior Art 
         [0006]    As compact digital devices have gained enormous popularity in recent decades, so has the need for better and more efficient ways of storing memory. Notable among memory devices are the portable ones that may be carried around by the user to access information on different devices at different locations. This is particularly common in the case of personal computers (PC), digital cameras, and portable digital music players, where the need often arises to transfer data from one device to another. Examples of portable memory devices include nonvolatile memory devices such as an SD memory card that is removably connectible to a computer. 
         [0007]    SD memory cards generally include a printed circuit board (PCB) or chip-on-board (COB) including memory or nonvolatile memory and/or other electronic devices. Packaging of the COB is particularly vital because of the popularity the COB has enjoyed largely due to allowing packing in a small PCB area. SD memory cards are used extensively in consumer devices and as consumer gadgets are requiring increasingly large amounts of memory there is a need to provide that memory quickly and cheaply. 
         [0008]    The need therefore arises for a single-sided memory card. 
       SUMMARY OF THE INVENTION 
       [0009]    Briefly, an embodiment of the present invention includes a single-sided memory card includes an injection- or transfer-molded base including the cavity, a thermal adhesive glue sheet position in the cavity, a PCBA secured inside the cavity of the single-sided memory card through the thermal adhesive glue sheet, and an adhesive label position on top of the PCBA, causing the PCBA to be protected and, after heating, the adhesive is cured binding the injection- or transfer-molded base. 
         [0010]    The foregoing and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments which make reference to several figures of the drawing. 
     
    
     
       IN THE DRAWINGS 
         [0011]      FIG. 1  a top side, bottom side, and exploded view of a single-sided memory card  100  is shown in accordance with an embodiment of the present invention. 
           [0012]      FIG. 2  shows further details of relevant components comprising the manufacture of the single-sided SD memory card. 
           [0013]      FIG. 3  shows further details of the Printed Circuit Board Assembly  104 . 
           [0014]      FIG. 4  shows the PCBA  104  being taped into a readied plastic base  200 . 
           [0015]      FIG. 5  shows a plastic (or paper) label  103  being applied to an unlabeled memory card  400 . 
           [0016]      FIG. 6  shows a top side, bottom side, and exploded view of a single-sided memory card with write-protect switch  600  in accordance with another embodiment of the present invention. 
           [0017]      FIG. 7  shows a top side, bottom side, and exploded view of a single-sided memory card with metal-case assembly  700  in accordance with another embodiment of the present invention. 
           [0018]      FIG. 8  shows further details of relevant components a single-sided memory card with metal-case assembly  700 , showing the metal-case completed metal base  800  construction. 
           [0019]      FIG. 9  shows further details of a single-sided memory card with metal case  700 , showing a thermal adhesive glue-sheet  105  being placed into a completed metal base  800  to form a tape-readied metal base  900 . 
           [0020]      FIG. 10  shows further details of a single-sided memory card with metal case  700 , showing a PCBA  104  being placed into tape-readied metal base  900  to form an unlabeled memory card with metal case  1000 . 
           [0021]      FIG. 11  shows further details of a single-sided memory card with metal case  700 , showing plastic (or paper) label  103  being placed on unlabeled memory card with metal case  1000  to form a single-sided memory card with metal case  700 . 
           [0022]      FIG. 12  shows a top side, bottom side, and exploded view of a single-sided memory card with over mold case assembly single-sided memory card with over-mold case  1200  in accordance with another embodiment of the present invention. 
           [0023]      FIG. 13  shows further details of relevant components comprising single-sided memory card with over-mold case  1200 . 
           [0024]      FIG. 14  shows thermal adhesive glue sheet  105  being placed into over-mold base  1300  to form unlabeled single-sided memory card with over-mold case  1500 . 
           [0025]      FIG. 15  shows PCBA  104  being placed into readied over-mold base  1400  to form unlabeled single-sided memory card with over-mold case  1500 . 
           [0026]      FIG. 16  shows plastic (or paper) label  103  being placed onto unlabeled single-sided memory card with over-mold case  1500  to form single-sided memory card with over-mold case  1200 . 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0027]    Referring now to  FIG. 1 , a top-view  101 , bottom-view  102 , and exploded-view  107  of a single-sided secure digital (SD) memory card  100  are shown in accordance with an embodiment of the present invention. The single-sided memory card  100  is shown to include an adhesive plastic (or paper) label  103 , a printed circuit-board assembly (PCBA)  104 , a thermal adhesive glue sheet  105 , and an injection- or transfer-molded plastic case  106 . The single-sided memory card  100  is generally shown to be rectangular in shape and in one embodiment of the present invention conforms to the standard dimensions for SD memory cards measuring 24 mm wide×32 mm long×2.1 mm thick. It should be noted, however, that in other embodiments and methods of building the memory cards, they may be made of varying dimensions and other such constructions. 
         [0028]    The plastic (or paper) label  103  is generally shown to be rectangular in shape in accordance with the present invention and is shown to include markings  103   a . These markings typically include text, graphics, pictures, or a combination thereof typically used to contain a company logo, association logo, version number, memory size, memory speed, or any other relevant or desired information. The plastic (or paper) label  103  also includes an insertion indicator  103   b  disposed near one corner of the label used to help the user of the single-sided memory card  100  to properly insert it into the host device. It should be noted, that this process is only an exemplary disposition and the indicator may be disposed anywhere on the label as long as the insertion indicator  103   b  indicates the proper insertion direction. In the embodiment of  FIG. 1 , the plastic (or paper) label  103  is also shown to have a tapered edge  103   c  to conform to the standards off the SD memory card. 
         [0029]    The PCBA  104  is also shown to be generally rectangular in shape in accordance with an embodiment of the present invention. The PCBA  104  is shown to have at a bottom surface thereof, contact pins  104   a . The host-contact pins are used to transfer information between the single-sided memory card  100  and the host device when the single-sided memory card  100  is coupled with the host device. In the embodiment of  FIG. 1 , the PCBA  104  is also shown to have a tapered edge  104   b  to conform to the standards off the SD memory card. 
         [0030]    The thermal adhesive glue sheet  105  is shown to be generally rectangular in shape in accordance with an embodiment of the present invention. The thermal adhesive glue sheet  105  is smaller in size than the plastic (or paper) label  103 , PCBA  104 , and injection- or transfer-molded plastic case  106  so that it can fit into the cavity  106   g.    
         [0031]    The injection- or transfer-molded plastic case  106  is shown to be generally rectangular in shape in accordance with an embodiment of the present invention. It is comprised of a plurality of lateral sides including the lateral side  106   a , leading lateral side  106   b , tapered lateral side  106   c , lateral side  106   d  and trailing lateral side  106   e . The sides lateral side  106   a , leading lateral side  106   b , tapered lateral side  106   c  and lateral side  106   d  and trailing lateral side  106   e  form a cavity  106   g  that holds the plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105 . Lateral side  106   a  is shown to have slits  106   f . The slits  106   f  are used to enhance user grip on the single-sided memory card  100  when, for example, the single-sided memory card  100  is being connected or removed from a host. 
         [0032]    Leading edge  106   b  and tapered edge  106   c  are attached to a series of plastic ribs  106   h . These plastic ribs are used to separate the contact pins  104   a  and to guide them into proper position when the single-sided memory card  100  is properly inserted into the host device. Tapered lateral side  106   c  facilitates proper insertion both by guiding the single-sided memory card  100  into a mating connector of a host when properly inserted but also by preventing full insertion into a host connector when it is improperly inserted. 
         [0033]    During assembly of the single-sided memory card  100 , the PCBA  104  is secured into the injection- or transfer-molded plastic case  106  via the thermal adhesive glue sheet  105 . The adhesive label  103  is placed on top of the PCBA  104  to form a PCBA sub-assembly. The adhesive plastic (or paper) label  103  is then placed on top of the PCBA sub-assembly. After the adhesive plastic (or paper) label  103  is placed on top of the PCBA  104 , the single-sided memory card  100  is heated for approximately 3-5 minutes at 160 degrees to cure the adhesive. 
         [0034]    In an exemplary application, the single-sided memory card  100  is removably connectable to a host device, such as a PC, digital camera, or other electronic device, for storing information in the memory included on the PCBA  104 . The single-sided memory card  100  is a compact device in large part due to surface mount technology (SMT) which requires no leads or wires for connecting electrical components. 
         [0035]    The single-sided memory card  100  is superior to previous methods of manufacturing memory cards because it single-sided, meaning it utilizes only a single injection- or transfer-molded plastic case  106 , instead of two. By requiring only a single injection- or transfer-molded plastic case  106  , the single-sided memory card  100  uses less material and utilizes fewer steps in construction. This, in turn, reduces cost and increases production speed. 
         [0036]    Referring now to  FIG. 2 , a readied plastic base  200  is shown to include the injection- or transfer-molded plastic base  106  and the thermal adhesive glue sheet  105  after the thermal adhesive glue sheet  105  has been inserted into the cavity  106   g  of the transfer- or injection-molded plastic case  106 . During a step in the manufacturing process of the single-sided memory card  100 , the thermal adhesive glue sheet  105  is placed into the cavity  106   g  of the injection- or transfer-molded plastic case  106  to form the readied plastic case  200 . 
         [0037]    Referring now to  FIG. 3 , a top-  300  and bottom-side  301  of the PCBA  104  is shown in accordance with an embodiment of the present invention. The single-sided PCBA is shown to include a tapered corner  104   b , contact pins  104   a , passive electrical components such as capacitors and resistors  301   a , controller chip  301   b , and memory module  301   c.    
         [0038]    Referring now to  FIG. 4 , an unlabelled memory card  400  is shown to include the PCBA  104  and readied plastic base  200  after the PCBA  104  has been inserted into the readied plastic base  200 . During a step in the manufacturing process, the PCBA is inserted into the readied plastic base to form the unlabelled memory card  400 . 
         [0039]    Referring now to  FIG. 5 , a single-sided memory card  100  is shown to include the unlabelled memory card  400  and the plastic (or paper) label  103  after the plastic (or paper) label  103  is applied to the unlabeled memory card. During a step in the manufacturing process the plastic (or paper) label  103  is applied to the unlabeled memory card to form the single-sided memory card  100 . 
         [0040]    Referring now to  FIG. 6 , a top-side  601 , bottom-side  602 , and exploded view  604  of a single-side memory card with write-protect switch  600  are shown in accordance with the present invention. The single-side memory card with write-protect switch  600  is shown to include plastic (or paper) label  103 , PCBA  104 , thermal adhesive glue sheet  105 , and injection- or transfer molded base with write-protect slot injection- or transfer molded base with write-protect slot  603 . The single-side memory card with write-protect switch  600  is generally shown to be rectangular in shape and in one embodiment of the present invention conforms to the standard dimensions for SD memory cards measuring 24 mm wide×32 mm long×2.1 mm thick. It should be noted, however, that in other embodiments of building the memory cards, they may be made of varying dimensions and other such constructions. 
         [0041]    The plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105  are identical and are described, supra pages 1-2. Further discussion here is avoided to reduce redundancy. 
         [0042]    The injection- or transfer molded base with write-protect slot  603  is shown to be generally rectangular in shape in accordance with an embodiment of the present invention. It is comprised of a plurality of sides including the lateral side  603   a , leading lateral edge leading lateral side  603   d , tapered lateral edge tapered lateral side  603   e , lateral side lateral side  603   f , and trailing lateral side trailing lateral side  603   g . Lateral side  603   a , leading lateral side  603   d , tapered lateral side  603   e , lateral side  603   f  and trailing lateral side  603   g  form cavity  603   i  that holds plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105 . Lateral side  603   a  is shown to have write-protect slot  603   b  into which write-protect switch  603   c  is inserted. Write-protect switch  603   c  allows the end-user to switch the card between read/write and read-only modes. Lateral side  603   f  has notch  603   h  that is part of the write-protect system. 
         [0043]    Leading lateral side  603   d  and tapered lateral side  603   e  are attached to plastic rib-structure  603   j . Plastic rib-structure  603   j  is used to separate contact pins  104   a  and to guide them into proper position when single-side memory card with write-protect switch  600  is properly inserted into the host device. Tapered lateral side  603   e  facilitates proper insertion both by guiding the single-side memory card with write-protect switch  600  into a mating connector of a host when properly inserted but also by preventing full insertion into a host computer when it is improperly inserted. 
         [0044]    During assembly of single-side memory card with write-protect switch  600 , PCBA  104  is secured into injection- or transfer molded base with write-protect slot  603  via thermal adhesive glue sheet  105 . plastic (or paper) label  103  is placed on top of PCBA  104  and single-side memory card with write-protect switch  600  is then heated for approximately 3-5 minutes at 160 degrees Celsius to cure the adhesive. 
         [0045]    In an exemplary application single-side memory card with write-protect switch  600  is removably connectable to a host device such as a PC, digital camera, or other electronic device for storing information in the memory included on PCBA  104 . Injection- or transfer molded base with write-protect slot  603  gives the user the option to set the invention in read/write or write-protect modes. single-side memory card with write-protect switch  600  is a compact device in large part due to SMT which requires no leads or wires for connecting electrical components. 
         [0046]    Referring no to  FIG. 7 , a top-view  701 , bottom-view  702 , and exploded-view  707  of single-sided memory card with metal case  700  are shown in accordance with an embodiment of the present invention. Single-sided memory card with metal case  700  is shown to include plastic (or paper) label  103 , PCBA  104 , thermal adhesive glue sheet  105 , metal frame  703 , plastic rib-structure  704 , and metal base  705 . Single-sided memory card with metal case  700  is shown to be generally rectangular in shape and in one embodiment of the present invention conforms to the standard dimensions for SD memory cards measuring 24 mm wide×32 mm long by 2.1 mm thick. It should be noted, however, that in other embodiments and methods of build the memory cards, they may be made of varying dimensions and other such constructions. 
         [0047]    Plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105  are identical and are described, supra pages 1-2. Further discussion here is avoided to reduce redundancy. 
         [0048]    Metal frame  703  is shown to be generally rectangular in shape in accordance with an embodiment or the present invention. Metal frame  703  is comprised of lateral side  703   a , leading lateral edge  703   b  tapered lateral edge  703   c , lateral edge  703   c , and lateral edge lateral edge  703   e . The underside of metal frame  703 , indicated as bottom view of the metal frame  706 , has slots for metal hooks  706   a.    
         [0049]    Plastic rib-structure  704  is shown to be generally rectangular in shape in accordance with an embodiment of the present invention. It measures a similar width to metal frame  703  and metal base  705 , but is shorter in order to fit between metal frame  703  and metal base  705 . It is comprised of plastic ribs  704   a  and tapered edge  704   b . Plastic ribs  704   a  are used to separate the contact pins  104   a  and to guide them into proper position when single-sided memory card with metal case  700  is properly inserted into the host device. 
         [0050]    Metal base  705  is shown to be rectangular in shape in accordance with an embodiment of the present invention. It is comprised of metal floor  705   a , metal hooks  705   b  and metal ribs  705   c . Metal floor  705   a  provides a platform for the placement of plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105 . 
         [0051]    During assembly of single-sided memory card with metal case  700 , metal frame  703  is placed above plastic rib-structure  704 . Plastic rib-structure  704  is in turn placed above metal base  705 . Metal hooks  705   b  on metal base  705  hook into the slots for metal hooks  706   a  on bottom view of the metal frame  706 , holding plastic rib-structure  704  in-between them. 
         [0052]    In an exemplary application, single-sided memory card with metal case  700  is removably connectable to a host device, such as a PC, digital camera, or other electronic device, for storing information in the memory included on PCBA  104 . Single-sided memory card with over-mold case  1200  is a compact device in large part due to the SMT which requires no leads or wires for connecting electrical components. 
         [0053]    Referring now to  FIG. 8 , completed metal base  800  is shown to include metal frame  703 , plastic rib-structure  704 , and metal base  705 . During a step of the manufacturing process, plastic rib-structure  704  is placed in-between metal frame  703  and metal base  705 . Metal frame  703  and metal base  705  are then snapped together to form completed metal base  800 , inclusive of cavity  800   a.    
         [0054]    Referring now to  FIG. 9 , a tape-readied metal base  900  is shown to be comprised of metal base  800  and thermal adhesive glue sheet  105  after thermal adhesive glue sheet  105  has been inserted into cavity  800   a  of completed metal base  800 . During a step in the manufacturing process of single-sided memory card with metal case  700 , thermal adhesive glue sheet  105  is placed into cavity  800   a  of completed metal base  800  to form a tape-readied metal base  900 . 
         [0055]    Referring now to  FIG. 10 , unlabeled memory card with metal case  1000  is shown to include PCBA  104  and a tape-readied metal base  900  after PCBA  104  has been placed into a tape-readied metal base  900 . During a step in the manufacturing process, PCBA  104  is placed into a tape-readied metal base  900  to form unlabeled memory card with metal case  1000 . 
         [0056]    Referring now to  FIG. 11 , single-sided memory card with metal case  700  is shown to include plastic (or paper) label  103  and unlabeled memory card with metal case  1000  after plastic (or paper) label  103  is placed on top of unlabeled memory card with metal case  1000 . During a step in the manufacturing process, plastic (or paper) label  103  is placed on top of unlabeled memory card with metal case  1000 . After plastic (or paper) label  103  is placed on top of unlabeled memory card with metal case  1000  to form single-sided memory card with metal case  700 , single-sided memory card with metal case  700  is heated for 3-5 minutes at 160 degrees Celsius to sure the adhesive. 
         [0057]    Referring now to  FIG. 12 , a top-side  1201 , bottom-side  1202 , and exploded  1207  view of single-sided memory card with over-mold case  1200  are shown in accordance with an embodiment of the present invention. Single-sided memory card with over-mold case  1200  is shown to include plastic (or paper) label  103 , PCBA  104 , thermal adhesive glue sheet  105 , plastic frame-guard bar  1203 , metal frame  1204 , and plastic base  1205 . Single-sided memory card with over-mold case  1200  is generally shown to be rectangular in shape and in one embodiment of the present invention conforms to the standard dimensions for SD memory cards measuring 24 mm wide by 32 mm long×2.1 mm thick. It should be noted, however, that in other embodiments and methods of building the memory cards they may be made of varying dimensions and other such constructions. 
         [0058]    Plastic (or paper) label  103 , PCBA  104 , and thermal adhesive glue sheet  105  are identical and is described, supra pages 1-2. Further discussion here is avoided to reduce redundancy. 
         [0059]    Plastic frame-guard bar  1203  has a tapered corner tapered corner  1203   a . Plastic frame-guard bar  1203  is used to slightly lift metal frame  1204  to prevent a short-circuit. 
         [0060]    Metal frame  1204  is shown to include leading lateral edge  1204   a , tapered lateral edge  1204   b , lateral edge  1204   c , trailing lateral edge  1204   d , and lateral edge  1204   e  in accordance with an embodiment of the present invention. Lateral edge  1204   e  is shown to have slits  1204   f . Slits  1204   f  is used to enhance user grip on single-sided memory card with over-mold case  1200  when, for example, single-sided memory card with over-mold case  1200  is being connected to or removed from a host device. 
         [0061]    Plastic base  1205  is shown to include plastic base floor  1205   a , plastic base tapered edge  1205   b , and plastic base plastic rib-structure  1205   c . plastic base tapered edge  1205   b  are used to separate the contact pins  104   a  and to guide them into proper position when single-sided memory card with over-mold case  1200  is properly inserted into a host device. Plastic base plastic rib-structure  1205   c  facilitates proper insertion both by guiding single-sided memory card with over-mold case  1200  into a mating connector of a host device. 
         [0062]    During assembly of single-sided memory card with over-mold case  1200 , PCBA  104  is secured into the case via thermal adhesive glue sheet  105 . The adhesive label is placed on top of PCBA  104 . After plastic (or paper) label  103  has been placed on top of PCBA  104 , single-sided memory card with over-mold case  1200  is heated for 3-5 minutes at approximately 160 degrees to cure the adhesive. 
         [0063]    In an exemplary application, single-sided memory card with over-mold case  1200  is removably connectable to a host device, such as a PC, digital camera, or other electronic device, for storing information in the memory included on the PCBA  104 . Single-sided memory card with over-mold case  1200  is a compact device in larger part due to the SMT which requires no leads or wires for connecting electrical components. 
         [0064]    Referring now to  FIG. 13 , over-mold base  1300  is shown to include plastic frame-guard bar  1203 , metal frame  1204 , and plastic base  1205  in accordance with an embodiment of the present invention. During a step in the manufacturing process plastic frame-guard bar  1203 , metal frame  1204 , and plastic base  1205  are pressed together to form over-mold base  1300 . 
         [0065]    Referring now to  FIG. 14 , readied over-mold base  1400  is shown to include plastic (or paper) label  103  and over-mold base  1300  in accordance with an embodiment of the present invention. During a step in the manufacturing process plastic (or paper) label  103  is placed onto over-mold base cavity  1300   a  to form readied over-mold base  1400 . 
         [0066]    Referring now to  FIG. 15 , unlabeled single-sided memory card with over-mold case  1500  is shown to include PCBA  104  and readied over-mold base  1400  in accordance with an embodiment of the present invention. During a step in the manufacturing process PCBA  104  is placed into readied over-mold base  1400   a  to form unlabeled single-sided memory card with over-mold case  1500 . 
         [0067]    Referring now to  FIG. 16 , single-sided memory card with over-mold case  1200  is shown to include plastic (or paper) label  103  and unlabeled single-sided memory card with over-mold case  1500  in accordance with an embodiment of the present invention. During a step of the manufacturing process, plastic (or paper) label  103  is placed on unlabeled single-sided memory card with over-mold case  1500  to form single-sided memory card with over-mold case  1200 .