Abstract:
A method of forming a radio frequency communication apparatus includes providing a substrate provided with an outermost surface. An RFID is adhered at least partially within the substrate, and the RFID includes an antenna and an integrated circuit. The RFID and substrate together form a radio frequency communication apparatus. A method of forming a radio frequency communication apparatus includes providing a substrate with a frontside surface. An opening is formed through the frontside surface and into the substrate. An RFID is inserted within the opening and adhered to the substrate within the opening. The RFID includes an antenna and an integrated circuit to form a radio frequency communication apparatus.

Description:
TECHNICAL FIELD 
     The invention pertains to radio frequency communication apparatuses and to methods of forming radio frequency communication apparatuses. 
     BACKGROUND OF THE INVENTION 
     Radio frequency communication apparatuses are devices configured for communicating with other devices through radio frequencies. Radio frequency communication apparatuses can comprise radio frequency identification devices (RFIDS). RFIDs are described in detail in U.S. patent application Ser. No. 08/705,043, filed Aug. 29, 1996, and incorporated herein by reference. RFIDs can comprise wireless communication circuitry or transponder circuitry for providing wireless communications with an interrogator unit. RFIDs can comprise integrated circuit chips. Such chips can contain, for example, a processor and memory. RFIDs comprising integrated circuitry may be referred to as intelligent RFIDs or as remote intelligent communication (RIC) devices. Radio frequency communication apparatuses can further comprise transmit and receive antennas electrically connected with an RFID. The antennas can be suitable for respectively transmitting and receiving wireless signals or RF energy. 
     Incorporating RFIDs into radio frequency communication apparatuses can be laborious and expensive. Accordingly, it is desirable to develop alternative methods for incorporating RFIDs into radio frequency communication apparatuses. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention encompasses a method of forming a radio frequency communication apparatus. A substrate is provided. The substrate has an outermost surface. An RFID is adhered to the substrate outermost surface. The RFID comprises an antenna and an integrated circuit. An entirety of the RFID is received outwardly of the substrate outermost surface. 
     In another aspect, the invention encompasses a method of forming a radio frequency communication apparatus. A substrate is provided. The substrate has a frontside surface. An opening is formed through the frontside surface and into the substrate. An RFID is inserted within the opening. The RFID is adhered to the substrate within the opening. The RFID comprises an antenna and an integrated circuit. 
     In another aspect, the invention encompasses a radio frequency communication apparatus. The apparatus comprises a substrate having an outermost surface. The apparatus further comprises an RFID adhered to the substrate outermost surface. The RFID comprises an antenna and an integrated circuit. An entirety of the RFID is received outwardly of the substrate outermost surface. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the invention are described below with reference to the following accompanying drawings. 
     FIG. 1 is a diagrammatic top view of a radio frequency communication apparatus produced according to a method of the present invention. 
     FIG. 2 is a diagrammatic cross-sectional side view of the FIG. 1 radio frequency communication apparatus taken along the line  2 — 2 , showing a radio frequency communication apparatus produced according to a first embodiment method of the present invention. 
     FIG. 3 is a diagrammatic cross-sectional side view of the radio frequency communication apparatus of FIG. 1 taken along the line  2 — 2 , and showing a radio frequency communication apparatus produced according to a second embodiment method of the present invention. 
     FIG. 4 is a diagrammatic cross-sectional side view of the radio frequency communication apparatus of FIG. 1 taken along the line  2 — 2 , and showing a radio frequency communication apparatus produced according to a third embodiment of the present invention. 
     FIG. 5 shows the radio frequency communication apparatus of FIG. 4, further processed according to a fourth embodiment of the present invention. 
     FIG. 6 is a diagrammatic cross-sectional side view of the FIG. 1 radio frequency communication apparatus taken along the line  2 — 2  and showing a fifth embodiment method of the present invention. 
     FIG. 7 is a diagrammatic top view of an RFID of the present invention. 
     FIG. 8 is a diagrammatic top view of the radio frequency communication apparatus of FIG.  4 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8). 
     FIG. 1 illustrates a radio frequency communication apparatus  10  of the present invention. Device  10  comprises a substrate  12  and an RFID  14  proximate substrate  12 . Substrate  12  can comprise a card having length and width dimensions corresponding to those of a credit card, and can comply with ISO 7816. For example, substrate  12  can have a length of from about 0.8 inch to about 6.75 inches, a width of from about 0.5 inch to about 4.25 inches, and a thickness of from about 0.010 inch to about 0.20 inch. Further, substrate  12  can comprise polyester, PVC and/or ABS, and can be substantially homogenous throughout an entirety of its construction. Substrate  12  consists of four peripheral quadrants, “A”, “B”, “C”, and “D”. Such four quadrants have substantially equal areas relative to one another. In the shown embodiment, RFID  14  is entirely contained within the quadrant “A”. 
     RFID  14  can be a chip comprising an integrated circuit and an antenna, and configured for communicating with an interrogator. RFID  14  will preferably also comprise a battery in electrical communication with the integrated circuit. Alternatively, as shown in FIG. 7, RFID  14  can comprise a substrate  70  upon which is adhered an integrated circuit chip  72 , an antenna  74 , and a battery  76 . Chip  72  and battery  76  are electrically interconnected to one another through conductive interconnects  78 . Chip  72 , battery  76  and antenna  74  can be covered with a protective surface, such as, for example, an encapsulant. Such protective surface can be provided prior to adhering RFID  14  to substrate  12 , or after adhering RFID  14  to substrate  12 . 
     In accordance with the present invention, RFID  14  can be mounted to substrate  12  in a variety of configurations. A first of the configurations is illustrated in FIG.  2 . Substrate  12  comprises a substantially planar outer surface  16  upon which is adhered RFID  14 . An entirety of RFID  14  is thus received outwardly of substrate outermost surface  16 . In the shown embodiment, RFID  14  covers a portion  18  of outer surface  16  and leaves another portion  20  uncovered, or exposed. In alternative embodiments which are not shown, RFID  14  can cover an entirety of outer surface  16 . RFID  14  can be adhered with, for example, an epoxy adhesive. 
     A second embodiment configuration of a radio frequency communication apparatus of the present invention is illustrated in FIG.  3 . In referring to FIG. 3, similar numbering to that used above in describing FIGS. 1 and 2 is utilized, with differences indicated by the suffix “a” or by different numerals. Radio frequency communication apparatus  10   a  comprises a substrate  12   a  having a frontside surface  22  and a backside surface  24 . An opening  26  is formed through frontside surface  22  and into substrate  12   a.  Opening  26  can be formed, for example, by molding the opening within substrate  12   a  as substrate  12   a  is formed. As another example, opening  26  can be formed by cutting the opening into substrate  12   a  after substrate  12   a  is formed. Opening  26  extends only partially into substrate  12   a  and comprises a periphery defined by an interior bottom surface  28  and by interior side surfaces  30 . 
     An RFID  14   a  is inserted within opening  26  and adhered to substrate  12   a.  RFID  14  has laterally outwardmost surfaces  31  laterally inward of interior side surfaces  30 . RFID surfaces  31  can be abutted against interior side surfaces  30 , but are more preferably displaced from the side surfaces  30  as shown. RFID surfaces  31  are preferably displaced from side surfaces  30  by a distance of less than or equal to about 3 mils when RFID  14  is approximately centered within opening  26 , and more preferably displaced by a distance of less than or equal to about 2 mils. Thus, if RFID  14  is abutted against a side surface  30 , rather than being approximately centered within opening  26 , the largest gap between a surface  31  and a side surface  30  will preferably be less than or equal to about 6 mils, and more preferably less than or equal to about 4 mils. The gaps between RFID surfaces  31  and side surfaces  30  can receive a bonding adhesive to adhere RFID  14  to substrate  12   a.  RFID  14   a  can be adhered to substrate  12   a  by adhesive applied to bottom surface  28  and/or to side surfaces  30 . 
     RFID  14   a  comprises a top surface  32 . In the shown embodiment, top surface  32  is above frontside surface  22  of substrate  12   a.  In alternate embodiments, top surface  32  of RFID  14   a  can be below frontside surface  22 , or substantially flush with frontside surface  22 . Such alternative embodiments can be formed by extending opening  26  further into substrate  12   a  than shown, or by utilizing a substrate  12   a  which is thicker relative to RFID  14   a  than the shown configuration. 
     A third embodiment configuration of a radio frequency communication apparatus of the present invention is described with reference to FIG.  4 . In referring to FIG. 4, similar numbering to that used in describing FIGS.  1 - 3  is utilized, with differences indicated by the suffix “b” or by different numerals. FIG. 4 is a cross-sectional view along the same line as that of FIG.  2 . FIG. 4 illustrates a radio frequency communication apparatus  10   b  comprising a substrate  12   b  and an opening  26   b  extending entirely through substrate  12   b.  RFID  14   b  comprises a top surface  32   b  and a bottom surface  34 . Top surface  32   b  is substantially flush with frontside surface  22   b  of substrate  12   b,  and bottom surface  34  is substantially flush with backside surface  24   b  of substrate  12   b.  In alternative embodiments, top surface  32   b  can extend above or below frontside surface  22   b,  and bottom surface  34  can extend above or below backside surface  24   b.    
     As shown in FIG. 8, opening  26   b  comprises a rectangular shaped internal periphery defined by sides  30   b.  RFID  14   b  comprises an external periphery having a rectangular shape complementary to the internal periphery shape of opening  26   b.  The external periphery of RFID  14   b  is defined by sides  31   b.  Each of sides  31   b  is proximate a side  30   b.  RFID  14   b  is preferably sized relative to opening  26   b  such that each of sides  31   b  is within about 3 mils of a proximate side  30   b  when RFID  14   b  is approximately centered within opening  26   b.  More preferably, RFID  14   b  is sized relative to opening  26   b  such that each of sides  31   b  is within about 2 mils of a proximate side  30   b  when RFID  14   b  is approximately centered within opening  26   b.  In practice, RFID  14   b  is placed within opening  26   b  with a mechanized system and adhered to substrate  12   b,  with, for example, epoxy. The slight displacement of sides  31   b  from sides  30   b  enables the epoxy to squeeze into gaps between sides  31   b  and  30   b  and adhere sides  31   b  and  30   b  to one another. 
     Radio frequency communication apparatus  12   b  can be further processed as shown in FIG.  5 . Laminating films  36  and  38  are provided over frontside surface  22   b  and backside surface  24   b,  respectively, of substrate  12   b.  Laminating films  36  and  38  extend over top surface  32   b  and bottom surface  34 , respectively, of RFID  14   b.  Laminating films  36  and  38  can comprise, for example, thin plastic sheets adhesively, or thermally, adhered to substrate  12   b  and RFID  14   b.    
     Laminating films  36  and  38  protect RFID  14   b  and substrate  12   b.  Also, laminating films  36  and  38  can aid in retaining RFID  14   b  within substrate  12   b.  Further, laminating films  36  and  38  can be printed with a message which is to be displayed on radio frequency communication apparatus  10   b.  Such message can be, for example, a set of instructions for use of radio frequency device  10   b,  or advertising. Laminating films  36  and  38  can both be formed after insertion of RFID  14   b  within substrate  12   b.  Alternatively, one of laminating films  36  or  38  can be formed before insertion of RFID  14   b  within substrate  12   b  and the other of laminating films  36  and  38  can be formed after such insertion. 
     Although laminating films are shown formed over both frontside surface  22   b  and backside surface  24   b,  in alternative embodiments a laminating film can be formed over only one of surfaces  22   b  and  24   b.  Also, although laminating films  36  and  38  are shown extending entirely over surfaces  32   b,    22   b,    24   b  and  34 , in alternative embodiments the laminating films may be formed to extend only partially over one or more of surfaces  32   b,    22   b,    34  and  24   b.  Laminating films  36  and  38  preferably extend entirely over surfaces  32   b  and  34  and at least over portions of surfaces  22   b  and  24   b  which are proximate to surfaces  32   b  and  34 . 
     An alternative construction of a radio frequency communication apparatus of the present invention is described with reference to FIG.  6 . In referring to FIG. 6, similar numbering to that used above in describing FIGS.  1 - 5  is utilized, with differences indicated by the suffix “c” or by different numerals. Radio frequency communication apparatus  10   c  comprises a substrate  12   c  having an opening  26   c  formed therethrough. Within opening  26   c  is an RFID  14   c.  RFID  14   c  has a top surface  32   c  which is above frontside surface  22   c  of substrate  12   c.  Radio frequency communication apparatus  10   c  further comprises a laminating film  38   c  formed over a backside surface  24   c  of substrate  12   c  and over a bottom surface  34   c  of RFID  14   c.  Laminating film  38   c  may be formed before or after insertion of RFID  14   c  within opening  26   c.  In alternative embodiments of the invention, a second laminating film could be formed over top surface  32   c  of RFID  14   c  and over frontside surface  22   c  of substrate  12   c.    
     The invention arose out of needs specifically associated with RFIDs. However, the artisan will appreciate that the invention can have application to smart cards. 
     In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.