Conductive Polymer RFID Antenna Direct Deposition
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Solution Overview
Problem
The existing manufacturing processes for RFID tags face challenges in aligning and connecting IC chip conductive pads with antennas, often resulting in complex and difficult assembly due to the small size of the connection points.
Innovation Solution
A method utilizing electrically conductive polymer is applied in a specific pattern over the IC chip and substrate, forming an antenna and enabling direct contact with the chip's pads, simplifying the connection process and attachment to a substrate, which can be flexible, using techniques like masking, screen printing, or ink jet printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate manufacturing and assembly methods are used for IC chip and antenna, then manufacturing flexibility is maintained, but alignment difficulty and assembly complexity increase
Solution Approach 1:
The patent merges the antenna manufacturing process with the IC chip assembly process by depositing conductive polymer directly on the substrate where the IC chip is placed. This integration eliminates the separate antenna fabrication and alignment steps, directly resolving the alignment precision and assembly complexity contradiction.
Solution Approach 2:
The IC chip is placed on the substrate before the antenna is formed. This preliminary positioning allows the antenna to be deposited in precise alignment with the chip pads, eliminating post-assembly alignment operations and reducing overall assembly complexity.
2Reliability
If conductive polymer is deposited in a pattern to form antenna, then connection reliability improves, but manufacturing process complexity increases
Solution Approach 1:
The conductive polymer material serves multiple functions simultaneously: it forms the antenna structure, provides electrical connection to the IC chip pads, and acts as an adhesive bonding layer. This multi-functionality improves connection reliability while avoiding the need for separate manufacturing steps for each function.
Solution Approach 2:
The patent uses composite conductive polymer materials that combine electrical conductivity with adhesive properties. This allows the antenna to be both electrically functional and mechanically bonded to the substrate and IC chip in a single deposited layer, resolving the contradiction between reliability and manufacturing ease.
3Stability of the object's composition
If rigid substrate is used for antenna fabrication, then structural stability is maintained, but flexibility and form factor options are reduced
Solution Approach 1:
The patent employs flexible substrates instead of rigid ones for antenna fabrication. The conductive polymer antenna deposited on these flexible substrates maintains structural stability while enabling the device to be bent, folded, or conformally mounted on various surfaces, thus achieving both stability and flexibility.
Solution Approach 2:
The patent changes the physical parameter of the substrate from rigid to flexible, which fundamentally alters the form factor options and adaptability of the RFID tag while maintaining the structural integrity needed for stable antenna operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly of RFID tags by ensuring accurate and reliable electrical connections between the IC chip and antenna, improving manufacturing efficiency and reducing alignment issues, while allowing for flexible and conductive polymer-based antenna fabrication with suitable sheet resistance.
Implementation Method 1
depositing an electrically conductive polymer on a portion of the second surface and the substrate in a first pattern such that the electrically conductive polymer in the first pattern contacts at least one of the one or more points of contact
Implementation Method 2
curing the electrically conductive polymer in the first pattern, wherein the electrically conductive polymer in the first pattern forms an antenna
Data Source
AI summary
Described are methods of making an electronic device, such as an RFID tag, including fabricating an antenna by depositing an electrically conductive polymer onto a substrate. The electrically conductive polymer is electrically connected to an electronic component, such as an IC chip or a diode. The electronic component may be placed on the substrate before or after the electrically conductive polymer is deposited. Once deposited, the electrically conductive polymer is cured. The electrically conductive polymer may be deposited in a number of ways, such using a mask having a desired pattern and applying the electrically conductive polymer to the mask, by screen printing the electrically conductive polymer or by printing the electrically conductive polymer using ink jet printing techniques.