Foil laminate intermediate and method of manufacturing

• US 9,876,265 B2
• Filed: 06/14/2011
• Issued: 01/23/2018
• Est. Priority Date: 06/14/2010
• Status: Active Grant

• Current Assignee: Avery Dennison Retail Information Services LLC (Avery Dennison Corporation)
• Original Assignee: Avery Dennison Retail Information Services LLC (Avery Dennison Corporation)
• Inventors: Forster, Ian J., Oelsner, Christian K., Revels, Robert, Kingston, Benjamin, Cockerell, Peter, Amon, Moris, Howard, Norman
• Primary Examiner(s): POLLEY, CHRISTOPHER M
• Application Number:
  US13/160,289
• Publication Number:
  US 20120064307A1
• Time in Patent Office: 2,415 Days
• Field of Search: 4281951
• CPC Class Codes: B23K 26/364 for making a groove or trench, e.g. for scribing a break initiation groove
• CPC Class Codes: B32B 2305/10 Fibres of continuous length
• CPC Class Codes: B32B 2307/302 Conductive
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2519/02 RFID tags
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: G06K 19/0723 the record carrier comprising an arrangement for non-contact communication, e.g. wireless communication circuits on transponder cards, non-contact smart cards or RFIDs
• CPC Class Codes: G06K 19/07718 the record carrier being manufactured in a continuous process, e.g. using endless rolls
• 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 19/0775 arrangements for connecting the integrated circuit to the antenna
• CPC Class Codes: G06K 19/07754 the connection being galvanic
• CPC Class Codes: G06K 19/07786 the antenna being of the HF type, such as a dipole
• CPC Class Codes: H01P 11/003 Manufacturing lines with conductors on a substrate, e.g. strip lines, slot lines
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making
• CPC Class Codes: Y10T 29/49018 with other electrical component
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49156 with selective destruction of conductive paths
• CPC Class Codes: Y10T 29/5317 : Laminated device
• CPC Class Codes: Y10T 29/53174 : Means to fasten electrical component to wiring board, base, or substrate
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24917 : including metal layer
• CPC Class Codes: Y10T 428/2809 : including irradiated or wave energy treated component
• CPC Class Codes: Y10T 428/2817 : Heat sealable

Abstract

The present invention relates to a method of manufacturing a metal foil laminate which may be used for example to produce an antenna for a radio frequency (RFID) tag, electronic circuit, photovoltaic module or the like. A web of material is provided to at least one cutting station in which a first pattern is generated in the web of material. A further cutting may occur to create additional modifications in order to provide additional features for the intended end use of the product. The cutting may be performed by a laser either alone or in combinations with other cutting technologies.

Claims

1. A foil laminate intermediate assembly, comprising:

a substrate having first and second face, a first and second longitudinally extending side edge, and a first and second transversely extending edge,

a plurality of registration marks provided on the first face of the substrate along one of the first and second longitudinally extending side edges or along one of the first and second transversely extending edges such that the plurality of registration marks are provided to assist in the cutting of an antenna structure;

a first pattern of adhesive provided in a form of at least a portion of circuit disposed on the first face of the substrate and adjacent the plurality of registration marks;

a metal foil applied over the pattern of adhesive that does not cover the plurality of registration marks; and

the metal foil having at least a first pattern corresponding to the first pattern of adhesive and the pattern of adhesive includes optical brighteners on top of the adhesive which are provided in a pattern to correspond to at least the first pattern in the metal foil wherein the antenna structure will have multiple contact points for one of either a direct attachment of a microprocessor or a strap containing a microprocessor and the first pattern of the metal foil is formed by laser cutting and is an antenna pattern for a radio frequency identification device.

2. The foil laminate intermediate assembly as recited in claim 1, wherein a carrier layer is provided on the second face of the substrate.

3. The foil laminate intermediate assembly as recited in claim 1, wherein the metal foil includes at least a second pattern distinct from the first pattern.

4. The foil laminate intermediate assembly as recited in claim 3, wherein the second pattern at least partially overlaps and is coincident with the first pattern.

5. The foil laminate intermediate assembly as recited in claim 1, wherein a reinforcement layer is provided between the metal foil and the pattern of adhesive.

6. The foil laminate intermediate assembly as recited in claim 1, wherein the pattern of adhesive includes optical brighteners ranging from about 0.1% to about 1% by weight of the pattern of adhesive.

7. The web as recited in claim 5, wherein the first pattern is an antenna pattern for a radio frequency identification device.

8. A web of foil laminate intermediate assemblies, comprising:

a web that includes a flexible substrate having first and second sides;

a plurality of foil laminate intermediates provided on the web;

the substrate having a plurality of registration marks along at least one of the first and second sides;

a pattern of adhesive disposed on the first face of the substrate and adjacent the plurality of registration marks, wherein the plurality of registration marks are each provided with an optical brightener within each registration mark and at least one foil laminate intermediate is aligned with at least one of the plurality of registration marks such that each of the plurality of foil laminate intermediates do not cover the plurality of registration marks;

a metal foil applied over the pattern of adhesive; and

the metal foil having at least a first pattern with the at least first pattern corresponding to the pattern of adhesive.

9. A web comprising;

a metal foil laminate, the metal foil laminate having a foil layer with fiducials formed in the foil layer, an adhesive layer beneath the foil layer and a substrate beneath the adhesive layer;

optical brighteners are provided in the layer of adhesive in a pattern to define cut marks;

a first cut in the metal foil laminate, to create a first conductive pattern, the first cut made by a laser;

a second cut in the metal foil laminate to create a second conductive pattern only in the foil layer, the second conductive pattern being distinct from the first pattern and the second cut being made by a laser.