Patent Publication Number: US-2003235027-A1

Title: Method of making interactive information closure and package

Description:
TECHNICAL FIELD  
       [0001] The present invention relates generally to a method of making an interactive information package comprising a closure and container, with the package including a microelectronics assembly, and more particularly to a method of making such a package by disposition of the microelectronics assembly within a mold, with subsequent formation of a plastic closure shell by molding generally about the microelectronics assembly.  
       BACKGROUND OF THE INVENTION  
       [0002] The development of integrated circuitry has permitted use of such devices in a wide range of applications. Use of such arrangements in a product package comprising a closure and container has a wide variety of applications, including product promotions, storage and dissemination of product information including product processing, and quality assurance, including tamper-indication, by monitoring the conditions within the product package. U.S. patent application Ser. No. 60/291,916, filed May 18, 2001, hereby incorporated by reference, discloses a product package including a closure and container, wherein the closure includes a microelectronics assembly configured for interaction with associated radio frequency “writers” and scanners.  
       [0003] A microelectronics assembly such as disclosed in the above-referenced patent application is configured for radio frequency interaction by the provision of a suitable radio frequency identification (RFID) integrated circuit, an antenna, and one or more inter-connectors operatively connecting the circuit and the antenna. The microelectronics assembly may include one or more micro-sensors, as well as a self-contained power source.  
       [0004] Cost-effective use of such interactive devices in packages including closures and containers requires that the microelectronics assembly be efficiently and economically positioned in the package, preferably generally at a top wall portion of the package&#39;s closure. In the past, common practice has been to supply microelectronics, and in particular RFID tags, embedded in or attached to a plastic substrate. Such a plastic substrate is typically supplied in large rolls to manufacturers of so-called “smart” products, such as smart credit cards and the like. Suitable machinery has been developed whereby the microelectronics assemblies can be efficiently inserted into products, such as by detachment from the substrate, or alternatively, by insertion of a portion of the substrate along with the microelectronics assembly into the product being manufactured.  
       [0005] The present invention is directed to a method of making an interactive information package, including a closure and container, wherein a microelectronics assembly is positioned in a mold cavity and a plastic closure subsequently molded therein so that the microelectronics assembly is integrated with the closure.  
       SUMMARY OF THE INVENTION  
       [0006] A method of making an interactive information closure for a package contemplates providing a mold assembly defining a mold cavity, and providing a microelectronics assembly that includes an RFID (radio frequency identification) integrated circuit, and optionally includes an antenna, and one or more interconnections. The present method further contemplates that the microelectronics assembly is positioned in the mold cavity, and that a plastic closure is then molded in the mold cavity so that the microelectronics assembly is integrated with the plastic closure. The plastic closure is formed to include a top wall portion, and an annular depending skirt portion, with the microelectronics assembly positioned in the mold so that the microelectronics assembly is positioned at either the exterior of the top wall portion of the closure, at the interior of the top wall portion of the closure, or encapsulated within the top wall portion.  
       [0007] In a further aspect of the present invention, the antenna and interconnections are formed on a surface of the top wall portion of the closure after molding, with the RFID integrated circuit positioned in the top wall portion. In one embodiment, the antenna and interconnections are formed directly on the surface of the top wall portion, such as by printing the antenna and interconnections on the surface with electrically conductive ink. The printing step can be selected from the group consisting of ink jet printing, silk screen printing, and offset printing.  
       [0008] Alternatively, the antenna and interconnections can be formed on the surface of the top wall portion by thin film deposition by evaporation or sputtering, with etching of the thin film, or laser machining of the thin film, effected to form the antenna and interconnections.  
       [0009] The present invention further contemplates that the antenna and interconnections of the microelectronics assembly can be formed on the surface of the closure by lamination, with either etching or laser machining of the lamination to form the antenna and interconnections of the microelectronics assembly on the inside surface of the closure.  
       [0010] The integrated circuit of the microelectronics assembly can be positioned either active-side down (sometimes referred to as “flip chip” placement) in the top wall portion of the closure, or active-side-up, in accordance with known manufacturing techniques utilizing wire bonding.  
       [0011] In another form of the present invention, the present method includes positioning the microelectronics assembly in the top wall portion of the closure (typically active-side-up), and forming a planarization layer over the integrated circuit. The method further contemplates forming one or more openings in the planarization layer, and forming the antenna of the assembly on the planarization layer, with interconnections formed through the openings in the layer. The antenna and interconnections can be formed by metal deposition followed by photolithography, with the step of forming the openings in the planarization layer including photolithography or laser machining.  
       [0012] The present invention further contemplates that the closure may be formed with a sealing liner positioned adjacent the inside surface of the top wall portion. When the microelectronics assembly is positioned on the interior of the top wall portion, the assembly is positioned between the top wall portion and the sealing liner. The sealing liner may be positioned within the closure by molding of the liner in situ within the closure.  
       [0013] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0014]FIG. 1 is a diagrammatic view of an interactive information package of the type that can be formed in accordance with the present invention, including a plastic closure and associated container;  
     [0015]FIG. 2 is a diagrammatic view of a radio frequency integrated circuit system for providing promotional and quality assurance functions; and  
     [0016]FIG. 3 is a diagrammatic view illustrating the method of making an interactive information closure and package in accordance with the present invention, wherein a microelectronics assembly is positioned within a mold cavity, for subsequent molding of a plastic closure for integration of the assembly therewith. 
    
    
     DETAILED DESCRIPTION  
     [0017] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments disclosed herein.  
     [0018] The present invention is directed to a method of making an interactive information package including a plastic closure and container, wherein a radio frequency integrated circuit and associated antenna are disposed within the package, preferably by disposition on an interior surface, exterior surface, or within a top wall portion of the plastic closure of the package. The arrangement of the present package facilitates its use for a variety of applications, including product promotion, storage and dissemination of product information including product processing information, and product quality assurance, including tamper-evidence. Use of packages formed in accordance with the present invention permits efficient inventory control, by permitting product purchases to be efficiently tracked without resorting to optical scanning of bar codes and the like.  
     [0019] As illustrated in FIG. 1, the package  10  which can be formed in accordance with the present invention comprises plastic closure  12  and an associated container  14  to which the closure can be secured, such as by cooperating, inter-engaged thread formations. Plastic closure  12  can be injection molded or compression molded, with U.S. Pat. No. 4,497,765, hereby incorporated by reference, disclosing a method and apparatus for efficiently compression-molding closures of this type.  
     [0020] The package  10  includes a radio frequency integrated circuit  16  (sometimes referred to as a radio frequency identification (RFID) device or tag) disposed within the package  10 , preferably by disposition on or at the interior surface of the closure  12 , that is, adjacent the inside surface of a top wall portion of the closure. The arrangement includes an antenna  18  operatively connected to the integrated circuit  16 , with the antenna cooperating with the integrated circuit to permit the integrated circuit to be externally powered without physical connection of a power supply thereto. The antenna  18  provides the desired radio frequency interface with an associated radio frequency input/output device  20  (FIG. 2) that can be configured to provide remote input to and/or reading and retrieval of electronic information carried by the integrated circuit  16 .  
     [0021] For purposes of the present disclosure, the term microelectronics, and microelectronics assembly, includes, but is not limited to RFID supporting electronics, antenna to support radio frequency communication, micro-sensors, and micro-power sources.  
     [0022] In accordance with the present disclosure, it is contemplated that the integrated circuit  16  and optional antenna  18 , and any associated components, including inter-connectors with the integrated circuit, be positioned within the closure  12  by disposition of the electronic components (referred to herein as a microelectronics assembly) within the closure  12 . As will be further described, the microelectronics assembly can be positioned within the closure  12  by embedding the assembly in the top wall portion thereof. It is contemplated that a sealing liner be provided for the closure, including molding of the liner within the closure, after the closure has been molded with the microelectronics assembly positioned in the top wall portion.  
     [0023] In the embodiment illustrated in FIG. 1, external powering of the integrated circuit precludes the need for an internal power supply operatively connected to the integrated circuit for providing electrical power thereto. However, for some configurations of the present package (such as providing tamper-evidence indication or capturing continuous historical data on package parameters such as pressure and/or temperature), it can be desirable to provide a compact power supply  22 , such as diagrammatically illustrated in FIG. 2, operatively connected to the integrated circuit  16 .  
     [0024] The microelectronics assembly of the package can be configured to include one or more different types of compact-size (i.e., micro) sensing devices. Such sensing devices may include, by way of example, a pressure sensor  24 , a temperature sensor  26 , a chemical sensor  28  for sensing the presence of chemicals such as oxygen, and/or a biological sensor  30  for sensing the presence of microorganisms within the package  10 . The configuration of the present package with one or more of the internal sensing devices greatly enhances versatile use of the present package for quality assurance functions, including tamper-evidence, brand protection, and anti-counterfeiting. An array of sensors can be provided for certain applications, with the array preferably integrated with radio frequency integrated circuit  16 . The provision of one or more sensors permits direct assessment of the quality state of the packaged goods.  
     [0025] U.S. patent application Ser. No. 60/291,916, hereby incorporated by reference, further describes use of the package  10  for specific applications.  
     [0026] It is contemplated that the microelectronics assembly used in practicing the present invention is provided in a package including a closure  12  by molding a plastic closure having a top wall portion, and a depending annular skirt portion, in a mold cavity of a mold assembly within which the microelectronics assembly has been previously positioned. The microelectronics assembly includes a radio frequency identification (RFID) integrated circuit, and optionally includes an antenna, and one or more interconnections.  
     [0027] In one embodiment of the present invention, the microelectronics assembly includes a previously-manufactured RFID integrated circuit, with the antenna and interconnections of the microelectronics assembly integral therewith.  
     [0028] In accordance with the present invention, a mold assembly  40 , including a female mold  42 , and a male mold plunger  44 , which together define a mold cavity  46 , is provided for formation of the plastic closure  12 . Closure formation can be effected by either injection molding or compression molding, as is known in the art. The microelectronics assembly is positioned within the mold cavity, such as by positioning on the male mold plunger  44 . The microelectronics assembly can be maintained in position prior to closure molding such as by the application of a vacuum to the assembly applied via suitable passages in the mold tooling. The plastic closure  12  is then molded within the mold cavity so that the closure is molded generally about the microelectronics assembly, which is thus embedded in and integrated with the closure.  
     [0029] When the microelectronics assembly is positioned on the male mold plunger  44  as illustrated, the resultant construction is such that the microelectronics assembly is positioned at the interior of the top wall portion of the plastic closure  12 . Alternatively, the microelectronics assembly can be positioned adjacent the inside surface of the female mold  42 , such that subsequent molding of plastic closure  12  results in the microelectronics assembly being positioned at the exterior of the top wall portion of the plastic closure. While disposition of the microelectronics assembly at either the interior or exterior surface of the top wall portion of the closure  12  is presently contemplated, it is within the purview of the present invention that the microelectronics assembly be positioned within a mold cavity such that the assembly is substantially encapsulated by the top wall portion of the closure. This can be effected by the provision of suitable stand-off elements or the like which act to maintain the microelectronics assembly in a position intermediate of, and spaced from, the interior surfaces of the female mold  42  and male mold plunger  44  during molding of the plastic closure.  
     [0030] In another embodiment of the present invention, the microelectronics assembly includes a previously-manufactured RFID integrated circuit, with the antenna and interconnections of the microelectronics assembly formed directly on either the outside or the inside surface of the top wall portion of the closure  12 . In one form of the invention, the antenna and interconnections are printed on the surface of the top wall portion with electrically conductive ink. The printing step can be selected from the group consisting of ink jet printing, silk screen printing, and offset printing. It is within the purview of the present invention to form the antenna and interconnections by laser writing, by which metallic conductive pathways are formed by employing a laser that “writes” in an organo-metallic gaseous atmosphere.  
     [0031] Alternatively, the antenna and interconnections of the microelectronics assembly can be formed by thin film deposition by evaporation or sputtering on the surface of the top wall of closure  12 . The thin film can be etched and/or laser machined to form the antenna and interconnections of the microelectronics assembly.  
     [0032] In a further alternative embodiment, the antenna and interconnections of the microelectronics assembly can be formed by lamination on the surface of the top wall portion of the closure  12 , again with etching and/or laser machining employed to form the antenna and interconnections of the microelectronics assembly on the surface.  
     [0033] In conjunction with formation of the antenna and interconnections of the microelectronics assembly on the surface of the top wall of the closure  12 , it is necessary to position the integrated circuit for operative association with the antenna and interconnections. Disposition of the integrated circuit can be effected by positioning active-side-down in the top wall portion of closure  12  with the pads of the integrated circuit being positioned for direct connection to the subsequently formed antenna or interconnections by soldering, stud-bump bonding, or use of a conductive adhesive, or by positioning of the integrated circuit active-side-up in the top wall portion of the closure and connecting the pads of the integrated circuit to the antenna or interconnections utilizing wire bonding techniques, depending upon the specific technique employed for formation of the associated antenna and interconnections.  
     [0034] In a further embodiment of the present invention, the step of forming the microelectronics assembly on the surface of the top wall portion of closure  12  includes first positioning the integrated circuit in the top wall portion of the closure (typically active-side-up), and forming a planarization layer over the integrated circuit. One or more openings are formed in the planarization layer, with the antenna of the assembly formed on the planarization layer, and interconnections formed through the openings in the planarization layer. When the present invention is practiced in this form, the antenna and interconnections can be formed by metal deposition, followed by photolithography, while the step of forming openings in the planarization layer can be effected by either photolithography or laser machining.  
     [0035] After the desired microelectronics assembly has been integrated into the top wall of closure  12 , it is ordinarily necessary to provide the required FDA barrier between the microelectronics and the contents of the closure&#39;s package. To this end, a sealing liner is positioned within the closure. If the microelectronics assembly is positioned at the interior surface of the top wall portion of the closure  12 , the microelectronics assembly is positioned between the top wall portion of the closure and the sealing liner. The sealing liner may be provided in the form of a pre-formed, disc-shaped sealing liner that is inserted into the closure shell after formation of the electronics assembly on the top wall portion thereof. Alternatively, the step of positioning the sealing liner in the closure can be effected by in situ molding of the sealing liner, such as by compression molding, within the closure.  
     [0036] From the foregoing, it will be observed that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.