RFID inlays and methods of their manufacture
First Claim
1. A method of manufacturing an RFID inlay, comprising:
- providing a strap substrate containing an RFID chip;
forming electrically conducting strap pad patterns that cover a portion of a first major surface of said strap substrate and electrical contacts of said RFID chip;
providing an inlay substrate having an electrically conductive antenna and antenna contact patterns; and
electroplating said strap pad patterns and said antenna contact patterns to form metal strap pads, metal antenna contacts, and a metal interconnect between said antenna contact patterns and said electrical contacts of said RFID chip.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of manufacturing RFID inlay structures includes providing a strap substrate containing an RFID chip. Strap pad patterns are formed adjacent said recessed regions over contacts of the RFID chip using a directly electroplateable resin (DER). The strap substrate is attached to an inlay substrate having an electrically conductive antenna and antenna contact patterns. The DER strap pad patterns, antenna pattern, antenna contacts and chip contacts are electroplated, thereby forming a metal interconnect between the contacts of the RFID chip and the antenna contacts on the inlay substrate. The strap substrate may be obtained from a web of strap substrates formed by a casting process. The DER material may be in the form of a DER ink and applied using a pen-plotter apparatus to form strap pad patterns or antenna coil patterns on the strap substrate, and to form antenna features and antenna contact patterns on the inlay substrate.
56 Citations
45 Claims
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1. A method of manufacturing an RFID inlay, comprising:
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providing a strap substrate containing an RFID chip;
forming electrically conducting strap pad patterns that cover a portion of a first major surface of said strap substrate and electrical contacts of said RFID chip;
providing an inlay substrate having an electrically conductive antenna and antenna contact patterns; and
electroplating said strap pad patterns and said antenna contact patterns to form metal strap pads, metal antenna contacts, and a metal interconnect between said antenna contact patterns and said electrical contacts of said RFID chip. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method of manufacturing strap substrates for an RFID inlay, comprising:
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providing a substrate;
placing a plurality of RFID chips onto said substrate; and
forming strap pad patterns or antenna coil patterns of directly electroplateable resin (DER) on said substrate, at least one of said DER strap pad patterns or DER antenna coil patterns having a terminal that is in electrical contact with an electrical contact of an RFID chip of said plurality of RFID chips. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. An RFID inlay structure, comprising:
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an inlay substrate having an antenna and antenna contacts;
a strap substrate carrying an RFID chip and having at least one surface coated with a directly electroplateable resin (DER), said DER being in electrical contact with said antenna contacts and contacts of said RFID chip; and
a metal interconnection electrically connected between the contacts of the RFID chip and the antenna contacts on the inlay substrate. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42)
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43. An RFID inlay structure, comprising:
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a substrate;
an RFID chip disposed on said substrate; and
a pattern of directly electroplateable resin (DER) formed on said substrate and on one or more electrical contacts of said RFID chip. - View Dependent Claims (44, 45)
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Specification