Manufacture of RFID tags and intermediate products therefor

• US 7,250,868 B2
• Filed: 03/08/2005
• Issued: 07/31/2007
• Est. Priority Date: 03/12/2004
• Status: Expired due to Fees

• Current Assignee: AK Stamping Company Inc.
• Original Assignee: AK Stamping Company Inc.
• Inventors: Kurz, Arthur A., Dunn, Wayne
• Primary Examiner(s): Hofsass; Jeffery
• Assistant Examiner(s): Labbees; Edny
• Application Number:
  US11/075,390
• Publication Number:
  US 20050198811A1
• Time in Patent Office: 875 Days
• Field of Search: 340/572.7, 340/572.5, 340/572.8, 296/01, 298/32, 298/46, 296/00
• US Class Current: 340/572.7
• 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 19/07779 the inductive antenna being a coil
• CPC Class Codes: G06K 19/07783 the coil being planar
• 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
• 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 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

An improvement in the manufacture of radio frequency identification tags employs an antenna stamped from a thin metallic sheet and affixed to a substrate at a first location to establish an intermediate product in which the stamped antenna is affixed to the substrate, and the intermediate product is placed at at least one subsequent location for further processing toward completion of a radio frequency identification tag.

Claims

1. In a method for manufacturing radio frequency identification tags having an electronic component connected electrically to an antenna, an improvement comprising the steps of:

stamping an antenna from a thin metallic sheet;

providing the antenna and a substrate with interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another, and engaging the complementary elements to locate the antenna and the substrate relative to one another;

affixing the stamped antenna to a substrate at a first location by adhering the antenna to the substrate with a thermally-activated adhesive and applying heat to activate the adhesive to establish an intermediate product comprising the antenna affixed to the substrate; and

placing the intermediate product at at least one subsequent location for further processing toward completion of a radio frequency identification tag.

2. The improvement of claim 1 wherein the complementary elements are provided by lancing.

3. In a method for manufacturing radio frequency identification tags having an electronic component connected electrically to an antenna, an improvement comprising the steps of:

stamping an antenna from a thin metallic sheet;

affixing the stamped antenna to a substrate at a first location by connecting the antenna to the substrate with a mechanical connection which includes providing the antenna and the substrate with interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another, and enqaging the complementary elements to affix the antenna to the substrate to establish an intermediate product comprising the antenna affixed to the substrate; and

placing the intermediate product at at least one subsequent location for further processing toward completion of a radio frequency identification tag.

4. The improvement of claim 3 including lancing the antenna and the substrate to establish the complementary elements.

5. The improvement of claim 3 wherein the complementary elements include tabs on the antenna and holes in the substrate, and the mechanical connection includes inserting the tabs into corresponding holes and subsequently crimping the tabs to secure the antenna in place on the substrate.

6. The improvement of claim 3 wherein the complementary elements include posts on the antenna and holes in the substrate, and the mechanical connection includes inserting the posts into corresponding holes and subsequently deforming the posts to secure the antenna in place on the substrate.

7. The improvement of claim 3 wherein the complementary elements include flaps in the substrate, and the mechanical connection includes overlapping the flaps with the antenna to secure the antenna in place on the substrate.

8. An intermediate product for the manufacture of radio frequency identification tags having an electronic component connected electrically to an antenna, the intermediate product comprising:

an antenna stamped from a thin metallic sheet; and

a substrate;

the antenna and the substrate including interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another;

the stamped antenna being affixed to the substrate with a thermally-activated adhesive for being placed at a prescribed location for further processing toward completion of a radio frequency identification tag.

9. The intermediate product of claim 8 wherein the complementary elements comprise lanced elements.

10. An intermediate product for the manufacture of radio frequency identification tags having an electronic component connected electrically to an antenna, the intermediate product comprising:

an antenna stamped from a thin metallic sheet; and

a substrate;

the antenna being affixed to the substrate with a mechanical connection including interengagable complementary elements carried by the antenna and the substrate for engagement to locate the antenna and the substrate relative to one another.

11. The intermediate product of claim 10 wherein the complementary elements comprise lanced elements.

12. The intermediate product of claim 10 wherein the complementary elements include tabs on the antenna and holes in the substrate, and the mechanical connection includes the tabs inserted into corresponding holes and crimped to secure the antenna in place on the substrate.

13. The intermediate product of claim 10 wherein the complementary elements include posts on the antenna and holes in the substrate, and the mechanical connection includes the posts inserted into corresponding holes and deformed to secure the antenna in place on the substrate.

14. The intermediate product of claim 10 wherein the complementary elements include flaps in the substrate, and the mechanical connection includes the flaps overlapped with the antenna to secure the antenna in place on the substrate.

15. In a method for manufacturing electronic devices having an electronic component connected electrically to an antenna, an improvement comprising the steps of:

stamping an antenna from a thin metallic sheet;

providing the antenna and the substrate with interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another, and engaging the complementary elements to locate the antenna and the substrate relative to one another;

affixing the stamped antenna to a substrate at a first location by adhering the antenna to the substrate with a thermally-activated adhesive and applying heat to activate the adhesive to establish an intermediate product comprising the antenna affixed to the substrate; and

placing the intermediate product at at least one subsequent location for further processing toward completion of an electronic device.

16. The improvement of claim 15 wherein the complementary elements are provided by lancing.

17. In a method for manufacturing electronic devices having an electronic component connected electrically to an antenna, an improvement comprising the steps of:

stamping an antenna from a thin metallic sheet;

affixing the stamped antenna to a substrate at a first location by connecting the antenna to the substrate with a mechanical connection which includes providing the antenna and the substrate with interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another, and engaging the complementary elements to affix the antenna to the substrate to establish an intermediate product comprising the antenna affixed to the substrate; and

placing the intermediate product at at least one subsequent location for further processing toward completion of an electronic device.

18. The improvement of claim 17 including lancing the antenna and the substrate to establish the complementary elements.

19. The improvement of claim 17 wherein the complementary elements include tabs on the antenna and holes in the substrate, and the mechanical connection includes inserting the tabs into corresponding holes and subsequently crimping the tabs to secure the antenna in place on the substrate.

20. The improvement of claim 17 wherein the complementary elements include posts on the antenna and holes in the substrate, and the mechanical connection includes inserting the posts into corresponding holes and subsequently deforming the posts to secure the antenna in place on the substrate.

21. The improvement of claim 17 wherein the complementary elements include flaps in the substrate, and the mechanical connection includes overlapping the flaps with the antenna to secure the antenna in place on the substrate.

22. An intermediate product for the manufacture of radio frequency identification tags having an electronic component connected electrically to an antenna, the intermediate product comprising:

an antenna stamped from a thin metallic sheet; and

a substrate;

the antenna and the substrate including interengagable complementary elements for engagement to locate the antenna and the substrate relative to one another;

the stamped antenna being affixed to the substrate with a thermally-activated adhesive for being placed at a prescribed location for further processing toward completion of a radio frequency identification tag.

23. The intermediate product of claim 22 wherein the complementary elements comprise lanced elements.

24. An intermediate product for the manufacture of electronic devices having an electronic component connected electrically to an antenna, the intermediate product comprising:

an antenna stamped from a thin metallic sheet; and

a substrate;

the antenna being affixed to the substrate with a mechanical connection including interengagable complementary elements carried by the antenna and the substrate for engagement to locate the antenna and the substrate relative to one another.

25. The intermediate product of claim 24 wherein the complementary elements comprise lanced elements.

26. The intermediate product of claim 24 wherein the complementary elements include tabs on the antenna and holes in the substrate, and the mechanical connection includes the tabs inserted into corresponding holes and crimped to secure the antenna in place on the substrate.

27. The intermediate product of claim 24 wherein the complementary elements include posts on the antenna and holes in the substrate, and the mechanical connection includes the posts inserted into corresponding holes and deformed to secure the antenna in place on the substrate.

28. The intermediate product of claim 24 wherein the complementary elements include flaps in the substrate, and the mechanical connection includes the flaps overlapped with the antenna to secure the antenna in place on the substrate.