Method and system for manufacturing radio frequency identification tag antennas

• US 20050151699A1
• Filed: 11/30/2004
• Published: 07/14/2005
• 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
• Granted Patent: US 7,370,808 B2
• Time in Patent Office: Days
• US Class Current: 343/867
• 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:

a casting surface having at least one antenna pattern extending therefrom;

a coating solution applicator that coats the casting surface at least in an area other than the at least one antenna pattern with a coating solution, wherein the casting surface deposits the coating solution onto a target sheet;

a curing agent that cures the coating solution on the target sheet to form at least one depression corresponding to the at least one antenna pattern; and

an antenna material applicator that fills 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 curing agent comprises an electron beam.

13. The system of claim 1, wherein the antenna material applicator 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.

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

15. The system of claim 13, wherein the conductive ink is high-energy radiation cured by the ink curing agent.

16. The system of claim 1, wherein the antenna material applicator comprises:

a metallic powder that fills the at least one depression.

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

(a) providing a casting surface having at least one antenna pattern extending therefrom;

(b) coating the casting surface at least in an area other than the at least one antenna pattern with a coating solution;

(c) applying the casting surface to a target sheet thereby depositing the coating solution onto the target sheet;

(d) curing the coating solution on the target sheet to form at least one depression corresponding to the at least one antenna pattern; and

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

18. The method of claim 17, wherein the casting surface is a surface of a cylinder, wherein step (c) 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.

19. The method of claim 17, wherein the casting surface is a surface of a plate, wherein step (c) comprises:

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

20. The method of claim 17, wherein step (d) comprises curing the coating solution while it is on the casting surface.

21. The method of claim 17, wherein step (d) is performed during step (c).

22. The method of claim 17, wherein step (b) comprises coating the casting surface with a polymer.

23. The method of claim 17, wherein step (b) comprises coating the casting surface with an acrylic.

24. The method of claim 17, wherein step (b) comprises coating the casting surface with a urethane.

25. The method of claim 17, wherein step (d) comprises:

curing the coating solution with an electron beam.

26. The method of claim 17, wherein step (e) 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.

27. The method of claim 26, wherein the curing step comprises thermally curing the conductive ink.

28. The method of claim 26, wherein the curing step comprises applying high-energy radiation to cure the conductive ink.

29. The method of claim 17, wherein step (e) comprises:

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

fusing the metal powder in the at least one depression.

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

a casting element having a surface that receives a conductive material, wherein the casting element is applied to a target sheet to dispose the conductive material thereon, thereby forming at least one antenna on the target sheet; and

a curing agent that cures the at least one antenna formed on the target sheet.

31. The system of claim 30, wherein the surface of the casting element has at least one antenna-shaped depression formed therein that receives the conductive material.

32. The system of claim 30, further comprising:

at least one raised antenna pattern on the surface of the casting element, the at least one raised antenna pattern having a sheet of the conductive material applied thereon;

wherein a plurality of antenna-shaped depressions are present on the target sheet, wherein the at least one raised antenna pattern causes respective areas of the sheet of the conductive material to be positioned in the depressions of the target sheet; and

wherein edges of the at least one raised antenna pattern cut the sheet of conductive material to leave antenna-shaped areas of the sheet of conductive material in the antenna-shaped depressions.

33. A method for manufacturing radio frequency identification (RFID) tag antenna, comprising:

receiving a conductive material on a surface of a casting element;

applying the casting element to a target sheet to dispose the conductive material thereon, thereby forming at least one antenna on the target sheet; and

curing the at least one antenna formed on the target sheet.

34. The method of claim 33, wherein said receiving step comprises receiving the conductive material in at least one antenna-shaped depression formed on the surface of the casting element.

35. The method of claim 33, wherein said applying step comprises:

causing respective areas of a sheet of the conductive material to be positioned into antenna-shaped depressions formed on the target sheet; and

cutting the sheet of conductive material to leave antenna-shaped areas of the sheet of conductive material in the antenna-shaped depressions.