RFID Smart Label with Reduced Layers and Method of Production

Abstract

An RFID smart label includes a plurality of layers, wherein one of the plurality of layers is an RFID inlay with a depression/recession region for holding the RFID chip/strap so that it does not extend above the surface of the antenna. The depressed/recessed region can have substantially the same depth as the thickness of the RFID chip/strap. High speed printing processes are then used to economically print labels on the RFID inlays having the RFID chip/strap embedded because there are no bumps to impede the printing process. A method for reliably and economically manufacturing a radiofrequency identification (RFID) antenna includes impressing a pattern on a surface of a substrate to make a first portion of the substrate having a positive image of the RFID antenna and a second portion of the substrate having a negative image of the RFID antenna, applying a release agent on the second portion of the substrate having a negative image of the RFID antenna, depositing a metallization layer over the surface of the substrate, applying a solvent over the metallization layer, and scraping the surface of the substrate causing mechanical interruption of the metallization layer. The release agent can be masking materials containing TiO2 or oil.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating a prior art layering scheme for fabricating RFID smart labels.

FIG. 2 is a diagram illustrating a layering scheme for fabricating RFID smart labels with fewer components, in accordance with one embodiment of the invention.

FIG. 3 is a block diagram illustrating a substantially conformal RFID, in accordance with another embodiment of the invention.

FIG. 4 is a block diagram illustrating a substantially conformal RFID with a gradually changing depression/recession region, in accordance with another embodiment of the invention.

FIG. 5 is a flowchart showing the steps used to manufacture a radiofrequency identification (RFID) antenna using patterning processes and release agents in accordance with one embodiment of the present invention.

FIG. 6 is a flowchart showing the steps of an alternative method used to manufacture a radiofrequency identification (RFID) antenna using patterning processes and release agents in accordance with another embodiment of the present invention.

Claims

1. An RFID smart label, comprising: a substrate with a depression/recession region;an RFID antenna deposited over said substrate;an RFIC located within said depression/recession region and not extending above said RFID antenna so that said RFIC and said RFID antenna form a substantially flat surface for directly printing information or graphics using a roll printer; andwherein the RFID smart label contains seven layers or less.

2. The RFID smart label of claim 1 further comprising information or graphics that has been directly printed on said RFIC and RFID antenna.

3. The RFID smart label of claim 1 wherein the RFID smart label contains less than seven layers.

4. The RFID smart label of claim 1 wherein said substrate is a roll.

5. The RFID smart label of claim 1 wherein said substrate is a polymer roll.

6. An RFID smart label, comprising: a release agent used as a release liner for removing other layers;an adhesive which has low strength to enable removal of said release agent;a substrate coupled to said adhesive, said substrate having a depression/recession region;an RFID antenna for receiving or transmitting signals; andan RFID chip/strap located in said depression/recession region and not extending above said RFID antenna so that said RFID chip/strap and said RFID antenna form a substantially flat surface for directly printing information or graphics using a roll printer.

7. The RFID smart label of claim 6 further comprising information or graphics that has been directly printed on said RFID chip/strap and RFID antenna.

8. The RFID smart label of claim 6 further comprising a passive component so that said RFID smart label does not have internal power.

9. The RFID smart label of claim 6 further comprising an active component and a power source for running said active component.

10. The RFID smart label of claim 6 wherein said release agent is a masking material comprising TiO2.

11. The RFID smart label of claim 6 wherein said release agent is a masking material comprising about ⅓ TiO2.

12. The RFID smart label of claim 6 wherein said release agent is a masking material comprising oil.

13. An RFID smart label, comprising: an RFID inlay having an exterior surface and a depression/recession region located in a substrate;wherein said RFID inlay is configured to support an RFIC or RFID chip/strap in said depression/recession region to be substantially conformal with said exterior surfaces of said RFID inlay for directly printing on said exterior surfaces of said RFID inlay information or graphics using a roll printer.

14. The RFID smart label of claim 13 further comprising information or graphics that has been directly printed on said exterior surfaces of said RFID inlay.

15. The RFID smart label of claim 13 wherein said depression/recession region has substantially the same depth as the thickness of said RFIC or RFID chip/strap.

16. The RFID smart label of claim 13 wherein said depression/recession region is deeper than the thickness of said RFIC or RFID chip/strap.

17. The RFID smart label of claim 13 wherein said substrate thickness ranges between 2 mils and 5 mils and wherein said RFIC or RFID chip/strap thickness is about 0.8 mils.

18. The RFID smart label of claim 13 wherein said depression/recession region has a depth ranging from between ⅓ and ¼ of the thickness of said substrate.

19. The RFID smart label of claim 13 wherein said depression/recession region is formed gradually by reducing the thickness of a substrate from a first thickness to a second thickness.

20. An RFID smart label, comprising: a substrate comprising: a first surface and a depression/recession region in said first surface, wherein said depression/recession region comprises a second surface that is substantially parallel to said first surface;a third surface connecting said first surface to said second surface, wherein said third surface is not perpendicular to either said first surface or to said second surface; andan RFIC or RFID chip/strap positioned on said second surface so that said RFIC or RFID chip/strap and said first surface form a substantially flat surface for directly printing information or graphics using a roll printer.

21. The RFID smart label of claim 20 further comprising information or graphics that has been directly printed on said RFIC or RFID chip/strap and said first surface.

22. The RFID smart label of claim 20 wherein said third surface has a length and width that is substantially longer than the length and the width of said second surface.

23. The RFID smart label of claim 20 wherein said length and width of said third surface is 3 to 4 times larger than the length and width of said second surface.

24. The RFID smart label of claim 20 wherein said second surface has a length and a width sufficiently large to hold said RFIC or RFID chip/strap.

25. The RFID smart label of claim 20 wherein said length and width of said third surface is 3 to 4 times larger than the length and width of said RFIC or RFID chip/strap.

26. The RFID smart label of claim 20 wherein said depression/recession region has substantially the same depth as the thickness of said RFIC or RFID chip/strap

27. A method of manufacturing an RFID smart label, comprising: providing a substrate to support an RFIC or RFID chip/strap;making a depression in said substrate for positioning said RFIC or RFID chip/strap in said depression; andpositioning said RFIC or RFID chip/strap in said depression so that said RFIC or RFID chip/strap is substantially conformal with an exterior surfaces of said substrate so that said RFIC or said RFID chip/strap and said exterior surface of said substrate form a substantially flat surface for directly printing information or graphics using a roll printer.

28. The method of claim 27 further comprising printing information or graphics directly on said RFIC or RFID chip/strap and said exterior surface of said substrate.

29. The method of claim 27 wherein said step of making a depression is done with debossing.

30. The method of claim 29 wherein said debossing further includes indenting approximately 15% to 35% of the surface of said substrate.

31. The method of claim 27 wherein said step of making a depression is done with thermoforming.

32. A method for manufacturing a radiofrequency identification (RFID) antenna, comprising: impressing a pattern on a surface of a substrate to make a first portion of the substrate having a positive image of the RFID antenna and a second portion of the substrate having a negative image of the RFID antenna;applying a release agent on the second portion of the substrate having a negative image of the RFID antenna;depositing a metallization layer over the surface of the substrate;applying a solvent over the metallization layer; andscraping the surface of the substrate causing mechanical interruption of the metallization layer.

33. The method of claim 32 further comprising forming projections in the second portion of the substrate having a negative image of the RFID antenna; said projections are higher then said second portion of the substrate.

34. The method of claim 33 wherein said step of forming projections in the second portion of the substrate further comprises forming bumps that protrude above the second portion of the substrate.

35. The method of claim 32 wherein said step of applying a release agent further comprises applying a masking material comprising TiO2.

36. The method of claim 32 wherein said step of applying a release agent further comprises applying a masking materials comprising about ⅓ TiO2.

37. The method of claim 32 wherein said step of applying a release agent further comprises applying a thin coat of a masking material comprising oil.

38. The method of claim 32 wherein said step of depositing a metallization layer further comprises vacuum depositing a metallization layer.

39. The method of claim 32 further comprising the step of applying a facestock using a roll printing process.

40. The method of claim 32 wherein said step of depositing a metallization layer is done using a bi-directional metallization.