FIELD OF THE INVENTION

[0001] The invention relates generally to RFID antenna assemblies and methods for forming RFID antenna assemblies.

BACKGROUND OF THE INVENTION

[0002] Radio-Frequency Identification (RFID) technology is directed to wireless communication between one object, typically referred to as a RFID tag, and another object, typically referred to as a RFID reader/writer. RFID technology has been adopted, and is increasingly being used, in virtually every industry, including, for example, manufacturing, transportation, retail, and waste management. As such, efficient RFID systems are becoming increasingly important as the demand for RFID technology increases.

[0003] RFID tags typically include two components: a RFID antenna assembly and an RFID integrated circuit (IC). RFID antennas can be used to receive and/or transmit an electromagnetic signal from a RFID reader/writer. A RFID IC (sometimes referred to as a RFID chip) can be used to store and/or process information (e.g., modulate/demodulate a radio-frequency (RF) signal).

[0004] Typically, RFID systems that operate in the ultra-high frequency (UHF) range utilize a standard dipole antenna configuration for the RFID antenna assembly. The performance of a standard dipole UHF transponder depends on the orientation between the transponder antenna and the reader antenna, because dipole antennas can only emit radio signals in one direction. To achieve two-dimensional readability, two or more dipole antennas can be used in a single antenna assembly. For example, two dipole antennas can be arranged perpendicular to each other to form a "double-dipole" antenna, which takes the shape of a cross. Standard "double-dipole" antennas require RPID chips with at least three electrical contact points: two antenna inputs and one ground contact. In other words, RPID chips require a separate channel for each dipole of the antenna assembly.

SUMMARY OF THE INVENTION

[0005] One approach to providing two-dimensional readability is to couple a near-field loop antenna with a dual polarized far-field antenna. In one aspect, there is an antenna assembly for two-dimensional readability. The antenna assembly includes a dual polarized far-field antenna and a near-field loop antenna electromagnetically coupled to the dual polarized far-field antenna. The near-field loop antenna includes two contacts for electrically connecting to a chip.

[0006] In another aspect, there is a method for forming an antenna assembly. The method includes forming, on a first side of a first substrate, a dual polarized far-field antenna, and forming, on a second side of a second substrate, a near-field loop antenna on a second layer. The near-field loop antenna includes two contacts for electrically connecting to a chip. The dual polarized far-field antenna is electromagnetically coupled to the near-field loop antenna.

[0007] In other examples, any of the aspects above can include one or more of the following features. The chip can include an RFID device. The dual polarized far-field antenna can be a UHF antenna. The near-field loop antenna can be inductively coupled to the dual polarized far-field antenna. The near-field loop antenna can be ohmically coupled to the dual polarized far-field antenna. The near-field loop antenna can be capacitively coupled to the dual polarized far-field antenna. The near-field loop antenna can be coupled to the dual polarized far-field antenna inductively, ohmically,

capacitively, or any combination thereof.

[0008] In some embodiments, the dual polarized far-field antenna can include a far-field loop antenna. The far-field loop antenna can include a rectangular geometry, a fractal geometry or a symmetrical geometry. The antenna assembly can further include the chip. The chip can be a one-channel chip. The chip can be a multi-channel chip comprising three or more contact pads. The antenna assembly can further include a first layer, a second layer, and a third layer. The first layer can include metallization of the dual polarized far-field antenna. The second layer can include a carrier material. The third layer can include metallization of the near-field loop antenna.

[0009] In other examples, the antenna assembly can further include a first layer and a second layer. The first layer can include a carrier material. The second layer can include metallization of the dual polarized far-field antenna and metallization of the near-field loop antenna. The antenna assembly can further include a first carrier material including the dual polarized far-field antenna, and a second carrier material including the near-field loop antenna.

[0010] In yet other embodiments, the method can further include ohmically coupling the dual polarized far-field antenna to the near-field loop antenna. The method can further include forming segments of the dual polarized far-field antenna and the near-field loop antenna, wherein the segments inductively couple the dual polarized far-field antenna to the near-field loop antenna. The method can further include forming segments of the dual polarized far-field antenna and the near-field loop antenna, wherein the segments capacitively couple the dual polarized far-field antenna to the near-field loop antenna. [0011] In yet other examples, the first and second substrates can be different and the method can further include positioning the first and second substrates together using lamination, dispensing, bonding, or any combination thereof. The first and second substrates can be the same and the first and second sides can be the same. The first and second substrates can be the same and the first and second sides can be different. The method can further include attaching the second substrate to a device, wherein forming the dual polarized far-field antenna can include printing the dual polarized far-field antenna over the second substrate attached to the device.

[0012] Any of the above implementations can realize one or more of the following advantages. By coupling a near-field loop antenna to a dual polarized far-field antenna, two-dimensional readable RPID tags can be made compatible with single-channel RFID chips. In addition, the RFID tags can remain compatible with multi-channel RFID chips.

[0013] The details of one or more examples are set forth in the accompanying drawings and the description below. Further features, aspects, and advantages of the invention will become apparent from the description, the drawings, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The advantages of the invention described above, together with further advantages, will be better understood by referring to the following description taken in conjunction with the accompanying drawings. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.

[0015] FIGS. 1A-1B are top views of a chip and a near-field loop antenna. [0016] FIGS. 2A-2F are top views of different antenna assembly configurations. [0017] FIGS. 3A-3C are cross-sectional side views of different antenna assembly substrate configurations of FIG. 2A.

[0018] FIGS. 4A-4B is a side view of a dual far-field antenna configuration. [0019] FIGS. 5A-5B are top views of different antenna assembly configurations.

DESCRIPTION OF THE INVENTION

[0020] FIG. IA is a top view of an exemplary chip 110. The chip 110 includes at least two contacts 112 and 114. The contact 112 can be, for example, an antenna port. The contact 114 can be, for example, a ground port. Combined, the contacts 112 and 114 can form a single channel for communicating with a remote reader (not shown) via an antenna assembly. In one embodiment, for example, the chip 110 can include a RFID IC

(sometimes referred to as a RFID chip). In a supplemental or alternative embodiment, the chip 110 can process UHF (ultra-high frequency) signals.

[0021] The chip 110 illustrated in FIG. IA includes two contacts positioned in separate corners, but other configurations can also be used. For example, the chip 110 can include additional contacts. In one embodiment, a chip 110 with additional contacts can be used as a multi-channel chip for use with an antenna assembly with two or more channels. For example, a chip with two pairs of contacts that are associated with two chip channels can be connected to an antenna assembly with two separate antenna channels, in which each chip channel transmits and/or receives electromagnetic signals via their respective antenna channel. In yet other configurations, the contacts 112 and 114 can be located at arbitrary positions on the chip 110.

[0022] FIG. IB is a top view of an exemplary near-field loop antenna 120. The near-field loop antenna 120 includes a gap 125 between the contact points 122 and 124. The contact points 122 and 124 can be used to connect to a channel on a chip. For example, the chip 110 can be coupled to the near-field loop antenna 120 by respectively attaching the contact points 122 and 124 to the chip contacts 112 and 114. In one embodiment, the near-field loop antenna 120 can be attached to the chip 110 using flip chip bonding. In another embodiment, the near-field loop antenna 120 can be attached to the chip 110 using wire bonding. In yet another embodiment, the near-field loop antenna 120 can be fabricated on the same substrate as the chip 110.

[0023] The near-field loop antenna 120 illustrated in FIG. IB is configured as a circular loop, but other configurations can also be used. In one embodiment, for example, the near-field loop antenna 120 can be configured as a square loop or as any rotationally symmetric loop. More generally, the near-field loop antenna 120 can be configured in any arbitrary loop path. In some embodiments, the length of the near-field loop antenna 120 can be between 15 mm and 120 mm. The length of the near-field loop antenna 120 can depend on the electrical characteristics of the RFID chip (e.g., impedance, inductivity and/or capacitance).

[0024] FIGS. 2A-2F are top views of different antenna assembly configurations 200. The antenna assembly 200a includes a dual polarized far-field antenna 210 and a near-field loop antenna 120. A chip 110 can be connected to the near-field loop antenna 120. The dual polarized far-field antenna 210 advantageously can receive and/or transmit electromagnetic waves independent of the polarization of the electric field incident on the plane of the antenna 210. In some embodiments, the length of the dual polarized far-field antenna 210 can be between 240 mm and 400 mm. The length of the far-field antenna 210 can depend on the electrical characteristics of the RFID chip, the quality factor of the coupling to the far-field antenna, and/or the application (e.g., based on the mounting of an RFID tag to any surface resulting in any detuning). Therefore, the resonance frequency of a RFID tag, and consequently the length of the far-field loop 210, can be dependent on the application.

[0025] The near-field loop antenna 120 can be positioned into a corner 212 of the dual polarized far-field antenna 210 such that the two antennas are magnetically coupled to each other. For example, the near-field loop antenna 120 can be magnetically coupled to the dual polarized far-field antenna 210 via the magnetic induction that results from the proximity of segments of the two antennas in corner 212. In some configurations, the near-field loop antenna 120 can overlap with the dual polarized far-field antenna 210 or a gap can exist between the two. In a supplemental or alternative embodiment to inductive coupling, the near-field loop antenna 120 can be ohmically and/or capacitively coupled to the dual polarized far-field antenna 210. For example, the antenna assemblies 200b and 200c include a dual polarized far-field antenna 220 that is ohmically connected to the near-field loop antenna 120 via connections in corners 222b and 222c. Generally, the far- field antenna 210 can connect to at least one point anywhere on the near-field antenna 120 (e.g., the point that is substantially opposite to the chip's position).

[0026] In the antenna assembly configurations 200a-c, the dual polarized far-field antennas 210 and 220 are configured as rectangular loops, but other configurations can also be used. In one embodiment, for example, a dual polarized far-field antenna can be configured as any rotationally symmetric loop. More generally, a dual polarized far-field antenna can be configured in any arbitrary loop path. In some embodiments, for example, an antenna assembly configuration 20Od or 20Oe can include a rectangularly-shaped dual polarized far-field antennas 23Od or 23Oe with semi-circle indentations 232 located on each side. In an alternative embodiment, an antenna assembly configuration 240 can include a dual polarized far-field antenna 240 with a fractal geometry. The near-field loop antenna 120 can be positioned, for example, in the center of the dual polarized far- field antenna 240, which would allow substantially all segments of the near-field loop antenna 120 to be magnetically coupled to segments 242 of the dual polarized far-field antenna 240.

[0027] In general, near-field loop antennas and dual polarized far-field antennas can be formed on one or more substrates. Formation of an antenna can include metallization of a side of the substrate. Suitable substrates can include a non-conductive carrier material such as, for example, PET (polyester), FR-4 (or any other printed circuit board (PCB) material), PI (polyimide), BT (bismaleimide-triazine), PE (polyethylene), PVC

(polyvinylchloride), PC (polycarbonate), Teslin (silica-filled polyethylene), paper and/or other suitable antenna substrate materials. In addition, substrates can be flexible or rigid. In one embodiment, a near-field loop antenna and a dual polarized far-field antenna can be formed on the same side of a substrate. In an alternative embodiment, a near-field loop antenna and a dual polarized far-field antenna can be formed on different sides of a substrate. In yet another embodiment, a near-field loop antenna and a dual polarized far- field antenna can be formed on different substrates and subsequently brought together using lamination, dispensing, bonding, and/or any other substrate binding process.

[0028] In another embodiment, a RFID chip can be bonded to a near-field loop (e.g., an antenna on a carrier material like PET), and the far-field antenna can be printed on the top-side or bottom-side of the carrier material. In yet another embodiment, a RFID chip can be bonded to a near-field loop (e.g., an antenna on a carrier material like PET), and the near-field loop can be laminated, dispensed, bonded, or otherwise attached to any device (e.g., a cardboard box or other housing). A far-field loop antenna can be printed on top of the device to which the near-field loop is attached to.

[0029] FIGS. 3A-3C are cross-sectional side views of exemplary antenna assembly substrate configurations 300 using, for example, the antenna assembly 200a along the cross-section 301. In antenna assembly substrate configuration 300a, the near-field loop antenna 120 and the dual polarized far-field antenna 210 were formed on different sides of a substrate 310, and can be inductively, capacitively, and/or ohmically coupled to one another. In antenna assembly substrate configuration 300b, the near-field loop antenna 120 and the dual polarized far-field antenna 210 were formed on the same side of a substrate 320, and can be inductively, capacitively and/or ohmically coupled to one another. In antenna assembly substrate configuration 300c, the near-field loop antenna 120 and the dual polarized far-field antenna 210 were formed, respectively, on substrates 330a and 330b. Substrates 330a and 330b can, for example, be brought together such that the near-field loop antenna 120 and the dual polarized far-field antenna 210 are inductively, capacitively, and/or ohmically coupled to one another. In one embodiment, a material, such as an insulator, can separate substrates 330a and 330b. The substrates 300a and 300b can be brought together in any configuration (i.e., the surfaces on which the antennas were formed can both point away from each other, can both point towards each other, or can both point in the same direction).

[0030] In some embodiments, a dual polarized far-field antenna can be coupled to one or more additional dual polarized far-field antennas via inductive, capacitive, and/or ohmic coupling. FIGS. 4A-B are views of a dual far-field antenna assembly 400a. The dual far- field antenna assembly 400a includes the dual polarized far-field antenna 210 and near- field loop antenna 120 as illustrated in FIG. 2A with an additional dual polarized far-field antenna 410. The dual polarized far-field antenna 410 can be inductively coupled to the dual polarized far-field antenna 210. The dual far-field antenna assembly 400a can be positioned on a device 420 (e.g., a cardboard box or other container) such that each far- field antenna is aligned with a different surface or direction. Providing different directional alignments of multiple far-field antennas advantageously can allow for better readability between a RFID tag and a RFID reader/writer.

[0031] FIGS. 5A-5B are top views of different antenna assembly configurations 500. The antenna assembly 500a includes a dual polarized far-field antenna 510 and a near- field loop antenna 120. The antenna assembly 500b includes a dual polarized far-field antenna 530 and a near-field loop antenna 120. A chip 110 can be connected to the near- field loop antenna 120. The near-field loop antenna 120 can be positioned into a corner of the dual polarized far-field antenna 510 such that the two antennas are magnetically, ohmically, and/or capacitively coupled to each other. In alternative embodiments, a near- field loop antenna can be positioned in any location where it is coupled to a far-field antenna, such as, for example, in FIG. 2F.

[0032] In the antenna assembly 500a, the dual polarized far-field antenna 510 includes tuning elements 520. In the antenna assembly 500b, the dual polarized far-field antenna 530 includes tuning elements 540. In general, one or more tuning elements can be added to a far-field antenna to increase the far-field antenna's effective capacitance. For example, one or tuning elements can be designed to provide the far-field antenna with a predetermined capacitance. Tuning elements can advantageously reduce the total antenna size and/or improve the read range based on the addition of capacitance to the antenna assembly configuration.

[0033] In some embodiments, one or more tuning elements can be formed with a far-field antenna in one or more metallization steps, wherein the tuning element(s) are formed by depositing metal to form extra surface area with respect to the far-field antenna. In some embodiments, the tuning elements can be formed to be symmetric with each other from a top-view perspective of the substrate. [0034] In some embodiments, such as in antenna assemblies 500a and 500b, the minimum width of a tuning element is at least three times the width of the metalized path of the far-field antenna. In supplemental or alternative embodiments, such as in antenna assembly 500b, segments of tuning elements are coupled tangentially to the far-field antenna.

[0035] In the antenna assembly configurations 500a-b, the dual polarized far-field antennas 510 and 530 are configured as rectangular loops, but other configurations can also be used. In general, a dual polarized far-field antenna can be configured in any arbitrary loop path.

[0036] In supplemental or alternative embodiments one or more tuning elements can be added to a far-field antenna to increase the far-field antenna's effective inductance. For example, one or tuning elements can be designed to provide the far-field antenna with a predetermined inductance. In general, an inductive tuning element can include any indentation and/or any element that increases the circumference of the far-field loop antenna. For example, inductive tuning elements can include semi-circle indentations 232 and/or indentations that include segments 242. Inductive tuning elements can advantageously reduce the total antenna size and/or increase performance of the antenna due to frequency optimization.

[0037] One skilled in the art will realize the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.