RFID device and method of forming

• US 7,102,520 B2
• Filed: 06/18/2004
• Issued: 09/05/2006
• Est. Priority Date: 12/31/2002
• Status: Active Grant

• Current Assignee: Avery Dennison Retail Information Services LLC (Avery Dennison Corporation)
• Original Assignee: Avery Dennison Corporation
• Inventors: Forster, Ian J., Weakley, Thomas Craig, Munn, Jason, Liu, Peikang
• Primary Examiner(s): Ho, Tan
• Assistant Examiner(s): AL NAZER, LEITH A
• Application Number:
  US10/871,136
• Publication Number:
  US 20050035924A1
• Time in Patent Office: 809 Days
• Field of Search: 343/700.MS, 343/873, 343/895, 340/572.1, 340/572.7, 340/572.8, 257/673
• US Class Current: 340/572.1
• CPC Class Codes: G06K 19/07749 the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card
• CPC Class Codes: G06K 19/07752 using an interposer
• CPC Class Codes: H01L 2924/15153 the die mounting substrate comprising a recess for hosting the device
• CPC Class Codes: H01Q 1/2225 used in active tags, i.e. provided with its own power source or in passive tags, i.e. deriving power from RF signal
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 7/00 Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop

Abstract

A radio frequency identification (RIFD) inlay includes an interposer that has a chip, and an antenna on an antenna substrate. The antenna substrate has a recess or hole, and the chip is at least partially in the recess or hole. By placing the chip or the interposer face down and at least partially in a recess or hole, thickness of the inlay may be reduced.

Claims

1. A radio frequency identification (REID) device comprising:

an antenna substrate having at least a recess therein;

an antenna on the antenna substrate; and

an interposer, wherein the interposer includes;

an RFID chip having contacts thereupon; and

interposer leads operatively coupled to the contacts of the chip;

wherein the interposer leads and the antenna are electrically coupled together;

wherein at least part of the interposer is within the at least a recess; and

wherein the interposer leads and the antenna are capacitively coupled together across a dielectric material.

2. The device of claim 1, wherein the dielectric material is a dielectric layer.

3. The device of claim 1, wherein the dielectric material is an adhesive layer.

4. The device of claim 1, wherein the at least a recess is bounded by a thinned portion of the antenna substrate.

5. The device of claim 1, wherein the at least a recess is a hole through the antenna substrate.

6. The device of claim 5, wherein the hole is a punched hole through the antenna substrate.

7. The device of claim 5, wherein part of the interposer passes through the hole.

8. The device of claim 7,

wherein the interposer leads are on a first side of the antenna substrate;

and

wherein at least part of the chip is on an opposite side of the antenna substrate.

9. The device of claim 5, wherein no part of the interposer passes fully though the hole.

10. The device of claim 5, wherein the hole is a variable-dimension chip-receiving hole that is configured to expand to receive the at least part of the chip.

11. The device of claim 10,

wherein the interposer includes a pair of protruding posts on opposite respective sides of the chip;

and

wherein the antenna substrate has a pair of variable-dimension post-receiving holes that receive the posts therein.

12. The device of claim 11, wherein portions of the interposer leads on the posts are located in the post-receiving holes.

13. The device of claim 12, wherein the portions of the interposer leads on the posts are in contact with electrically conductive material on inner edges of the post-receiving holes.

14. The device of claim 11, wherein the posts are mechanically clamped by the antenna substrate at the post-receiving holes.

15. The device of claim 1, wherein the chip has a greater thickness than that of the antenna substrate.

16. The device of claim 1, wherein the chip has a greater thickness than that of the remainder of the interposer.

17. The device of claim 1 wherein the interposer also includes an interposer substrate that is mechanically coupled to the interposer leads.

18. The device of claim 17, wherein the interposer substrate seals an open end of the at least a recess in the antenna substrate.

19. The device of claim 18,

wherein the at least a recess is a recess overlying a thinned portion of the antenna substrate;

and

wherein the chip is enclosed between the interposer substrate and the thinned portion of the antenna substrate.

20. A method of forming an RFID device, the method comprising:

forming an interposer, wherein the forming includes electrically coupling interposer leads of the interposer to contacts of an RFID chip of the interposer;

forming at least a recess in an antenna substrate that has an antenna thereupon; and

subsequent to the forming at least a recess, mechanically coupling the interposer and the antenna substrate together;

wherein the mechanically coupling includes placing at least part of the chip in the at least a recess; and

wherein the mechanically coupling also includes capacitively coupling the interposer leads and the antenna.

21. The method of claim 20, wherein the forming the at least a recess includes forming a recess in the antenna substrate that leaves a thinned portion of the antenna substrate beneath the recess.

22. The method of claim 21, wherein the mechanically coupling includes sealing the chip between the interposer substrate and the thinned portion of the antenna substrate.

23. The method of claim 20, wherein the forming the at least a recess includes forming a hole in the antenna substrate.

24. The method of claim 23, wherein the forming the hole includes punching out a portion of the antenna substrate.

25. The method of claim 23, wherein the mechanically coupling includes passing at least a portion of the chip fully Through the hole.