Method and system for manufacturing radio frequency identification tag antennas

• US 7,370,808 B2
• Filed: 11/30/2004
• Issued: 05/13/2008
• Est. Priority Date: 01/12/2004
• Status: Active Grant

• Current Assignee: Symbol Technologies, LLC (Zebra Technologies Corporation)
• Original Assignee: Symbol Technologies, Inc. (Zebra Technologies Corporation)
• Inventors: Eastin, David
• Primary Examiner(s): LE, UYEN CHAU N
• Application Number:
  US10/998,994
• Publication Number:
  US 20050151699A1
• Time in Patent Office: 1,260 Days
• Field of Search: 401/24, 408/00, 206/486, 235/492, 235/441, 235/451, 438/106
• US Class Current: 235/492
• 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: H01Q 1/2208 associated with components used in interrogation type services, i.e. in systems for information exchange between an interrogator/reader and a tag/transponder, e.g. in Radio Frequency Identification [RFID] systems methods or arrangements for sensing record carriers, e.g. for reading patterns G06K7/00; record carrier for use with machines and with at least a part designed to carry digital markings G06K19/00
• CPC Class Codes: H01Q 21/26 Turnstile or like antennas comprising arrangements of three or more elongated elements disposed radially and symmetrically in a horizontal plane about a common centre
• CPC Class Codes: H01Q 9/285 Planar dipole H01Q9/065 takes precedence; patch antenna H01Q9/0407
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making

Abstract

A method and system for manufacturing radio frequency identification (RFID) tag antennas is described. A casting surface is provided having at least one raised antenna pattern extending therefrom. The casting surface is coated at least in an area other than the at least one raised antenna pattern with a coating solution. The casting surface is applied to a target sheet thereby depositing the coating solution onto the target sheet. The coating solution is cured to form at least one depression corresponding to the at least one raised antenna pattern. The at least one depression is filled with a conductive material to form at least one antenna on the target sheet.

Claims

1. A system for manufacturing radio frequency identification (RFID) tag antennas, comprising:

means for coating a casting surface with a coating solution, the casting surface having at least one raised antenna pattern, wherein the coating solution is electron beam curable;

means for applying the casting surface to a target sheet thereby depositing the coating solution onto the target sheet, wherein the coating solution is not substantially deposited on the target sheet in areas corresponding to the at least one raised antenna pattern;

means for curing the coating solution on the target sheet to form at least one depression corresponding to the at least one raised antenna pattern, wherein the means for curing comprises an electron beam that cures the coating solution; and

means for filling the at least one depression with a conductive material to form at least one antenna on the target sheet.

2. The system of claim 1, wherein the casting surface is a surface of a cylinder that rolls against the target sheet to deposit the coating solution onto the target sheet.

3. The system of claim 1, wherein the casting surface is a surface of a plate that is applied to the target sheet to deposit the coating solution onto the target sheet.

4. The system of claim 1, wherein the coating solution is cured while on the casting surface.

5. The system of claim 1, wherein the coating solution is cured while the coating solution is being deposited by the casting surface.

6. The system of claim 1, wherein the coating solution is cured after the casting surface deposits the coating solution.

7. The system of claim 1, wherein the coating solution comprises a polymer.

8. The system of claim 1, wherein the coating solution comprises an acrylic.

9. The system of claim 1, wherein the coating solution comprises a urethane.

10. The system of claim 1, wherein the target sheet comprises polyester.

11. The system of claim 1, wherein the target sheet comprises paper.

12. The system of claim 1, wherein the means for filling comprises:

an ink depositor that coats the target sheet with a conductive ink;

a squeegee that squeegees the target sheet to concentrate the conductive ink in the at least one depression; and

an ink curing agent that cures the conductive ink in the at least one depression.

13. The system of claim 12, wherein the conductive ink is thermally cured by the ink curing agent.

14. The system of claim 12, wherein the conductive ink is high-energy radiation cured by the ink curing agent.

15. The system of claim 1, wherein the means for filling comprises:

a metallic powder that fills the at least one depression.

16. A method of manufacturing radio frequency identification (RFID) tag antennas, comprising:

(a) coating a casting surface with a coating solution, the casting surface having at least one raised antenna pattern, wherein the coating solution is electron beam curable;

(b) applying the casting surface to a target sheet thereby depositing the coating solution onto the target sheet, wherein the coating solution is not substantially deposited on the target sheet in areas corresponding to the at least one raised antenna pattern;

(c) curing the coating solution on the target sheet with an electron beam to form at least one depression corresponding to the at least one raised antenna pattern; and

(d) filling the at least one depression with a conductive material to form at least one antenna on the target sheet.

17. The method of claim 16, wherein the casting surface is a surface of a cylinder, wherein step (b) comprises:

(1) moving the target sheet in a first direction; and

(2) rotating the cylinder against the moving target sheet to deposit the coating solution onto the target sheet.

18. The method of claim 16, wherein the casting surface is a surface of a plate, wherein step (b) comprises:

applying the plate to the target sheet to deposit the coating solution onto the target sheet.

19. The method of claim 16, wherein step (c) comprises curing the coating solution while it is on the casting surface.

20. The method of claim 16, wherein step (c) is performed during step (b).

21. The method of claim 16, wherein step (a) comprises coating the casting surface with a polymer.

22. The method of claim 16, wherein step (a) comprises coating the casting surface with an acrylic.

23. The method of claim 16, wherein step (a) comprises coating the casting surface with a urethane.

24. The method of claim 16, wherein step (d) comprises:

coating the target sheet with a conductive ink;

squeegeing the target sheet to concentrate the conductive ink in the at least one depression; and

curing the conductive ink in the at least one depression.

25. The method of claim 24, wherein curing the conductive ink in the at least one depression comprises thermally curing the conductive ink.

26. The method of claim 24, wherein curing the conductive ink in the at least one depression comprises applying high-energy radiation to cure the conductive ink.

27. The method of claim 16, wherein step (d) comprises:

filling the at least one depression with a metallic powder; and

fusing the metal powder in the at least one depression.