Rotary screen printing method for manufacturing an antenna
The present invention relates to a method for manufacturing antennas made from electrically conductive metal on a substrate by means of screen printing.
A method of this type is known, for example, from WO 01/04834 as a step in manufacturing admission tickets. In this known method, a number of tickets which provide admission to a monitored zone are manufactured from a web of paper which is unwound from a stock reel. An electronic module for each ticket is applied to the paper web. The electronic module comprises an integrated circuit and an antenna. The antenna is made from an ink, which comprises silver powder in a polymerizable matrix, by means of screen printing. Paper as starting material for the substrate has been selected with a view to costs. The paper web has the function of an electrically insulating substrate for the antenna. The ink is then allowed to dry and is subjected to a thermal treatment in order to obtain an antenna. To reduce the resistance of the antenna as much as possible, the thermal treatment comprises a laminating treatment at elevated pressure and temperature. To obtain a finished ticket, the known method also comprises a number of subsequent steps, including the application of connections for making contact with the integrated circuit, positioning the said circuit and shielding the electronic module fabricated in this way using protective layers .
One drawback of this known method is that a drying step and a thermal treatment are required at elevated pressure and temperature, which have an adverse effect on the duration of the method and increase costs .
French patent 2 769 440 has also disclosed a method for manufacturing an antenna, which is usually helical in shape. Antennas produced in this way are used, for example, as transponders in electronic memory cards and the like which can be read without contact, or hybrid cards, which can be read either without contact or with contact via fixed contact points. Examples include telephone cards, authorization badges, bank cards and other so-called smart cards for other purposes. In
these cards, information is exchanged between the memory chip of a card of this type and a reader by remote electromagnetic coupling between a first antenna, which is provided on the card, and a second antenna, which is provided in the reading/writing device. In the method for manufacturing the antenna which is known from the abovementioned French patent, an electrically conductive ink is likewise applied to an insulating substrate by means of screen printing. A conductive ink of this type comprises, for example, a metal particle content of between 60-95% in a polymeric matrix and a suitable solvent. According to the abovementioned French patent, it is possible for a plurality of antennas to be produced simultaneously on a substrate, after which the substrate is then divided into pieces, with an antenna on each piece. According to WO 98/11507, an integrated circuit can be applied by screen printing at the same time as the antenna. According to this patent publication an electrically conductive ink is used, which is laden with silver, copper or gold for the purpose of screen printing the antenna onto a substrate, for example a polymeric substrate. US-A 6,137,444 and DE-Al 19 511 300 also use silver-based conductive screen printing inks for manufacturing antennas of this type. WO 01/410161 has disclosed the screen printing of an antenna made from an ink containing silver powder onto a paper substrate as a substep in manufacturing smart cards, each smart card being printed and assembled separately. Furthermore, it is known in the art that preforms of antennas which have been deposited by means of screen printing, often in the form of coils comprising a plurality of turns, can be reinforced with a suitable metal by means of electroplating.
Another method for manufacturing antennas of this type is known, for example, from US patent 3,907,565, in which the antennas are etched from a foil, for example from a copper foil. The copper antennas formed in this way can, for example, be plated with tin in order to improve the soldering properties and the resistance to corrosion. Coating with tin in order to connect the antenna turn to a semiconductor chip is also proposed in US-A 5,809,633.
Antennas of this type, which can transmit and receive signals, should have a good conductivity, since no energy may be lost. A loss of energy means a reduction in the potential range.
The thickness of the antenna is often limited by the application, for example the total thickness of the card, which has to satisfy certain standards.
In the methods described above which use conductive ink, the solvent used has to be removed by drying after the screen printing, which requires relatively high temperatures. Many of the substrates used which are made from an organic polymer material are unable to withstand such a temperature, however, with the result that the physical properties and/or the appearance of the substrate are adversely affected. In addition, the conductivity of the antennas manufactured in this way leaves something to be desired, despite the aftertreatments used, such as a laminating step under certain circumstances at elevated temperature and elevated pressure.
It is an object of the present invention to provide a method for manufacturing antennas on a substrate by means of screen printing, in which the above problems do not occur or occur to a lesser extent. In particular, it is an object of the present invention to produce antennas with a high conductivity at low cost from inexpensive starting materials and with a high production rate. For this purpose, according to the invention the method for manufacturing antennas made from electrically conductive metal on a substrate by means of screen printing, comprises the steps of: unwinding a substrate web made of a flexible substrate material from a stock reel as the substrate which is to be printed, and using a rotary screen printing device to apply molten electrically conductive material to the substrate web in the form of antennas, the electrically conductive material being selected from an electrically conductive metal or metal compound.
Screen printing a molten electrically conductive metal or metal compound, such as an alloy, with a high conductivity without a liquid or pasty carrier which is subsequently to be removed, onto a substrate makes it possible to obtain antennas
with a high conductivity by a direct route, with the result that their range is good. Furthermore, there is no need for a drying step, and consequently it is almost impossible for the substrate to be adversely affected. Since a very thin layer of the metal or metal alloy with a high conductivity is applied, generally of the order of magnitude of at most 100 micrometers, this material will solidify immediately, and the heat transfer to the substrate is so low that it will not be adversely affected. This allows the use of a relatively inexpensive substrate material which does not have to satisfy any high requirements in terms of its resistance to heat. In this way, it is possible to select inexpensive starting materials both for the electrically conductive material which is to be melted in the method according to the invention and for the substrate, as will be explained in more detail below. Rotary screen printing has the advantage of being a continuous process in which a higher mass production rate can be obtained than with ordinary (i.e. flat) screen printing, which is a batch or semi-continuous (intermittent) process. This process also gives a high level of fineness, which is important with regard to the dimensions of the antenna, such as the width and thickness of the antenna turns and the distance between them. With regard to the production rate, in the method according to the invention the substrate is flexible, so that it can be unwound from a stock reel.
It should be noted at this point that DE-Al 199 47 376 has disclosed a method for producing what are described as "Skin- Kabelsatzen" . "Skin-Kabelsatzen" of this type are used to provide motor vehicles with electricity and comprise a plastic support, separate conductive tracks (which are not connected to one another) with a relatively great thickness and a covering of plastic. Each support, for example made from polyurethane, is produced separately in a mould by casting or foaming, and is then printed on, for example by screen printing a molten metal or metal alloy in order to form the tracks. Then, the covering, which is produced in the same way as the carrier, is applied to the latter.
In the method according to the invention the conductive material with a high conductivity is preferably selected from
metallic indium, metallic tin, metallic lead, bismuth, oxides thereof and the alloys and alloyed oxides, including indium tin oxide (ITO). Tin is advantageously used on account of its high conductivity and good resistance to corrosion, which are, for example, greater than those of silver. Tin is also a good fastening agent. Furthermore, tin has the advantage of a high elongation and flexibility at the thicknesses which are used for antennas, so that the substrate with the antennas applied to it can be wound up if desired. Furthermore, an antenna made from tin can be used in highly flexible cards. Indium has a relatively low melting point, approximately 160°C, which is advantageous with a view to energy costs in the method according to the invention.
The flexible substrate which is used in the method according to the invention may be a paper or polymer substrate. It is advantageous to use paper, which reduces production costs compared to the use of polymer substrates. If necessary, the substrate may be of a fire-retardant type.
In the method according to the invention, the antennas are applied to the substrate (in rows and/or columns) by means of rotary screen printing. Then, the substrate with the antennas on it is processed further, for example is wound up if possible or divided into substrate sections which comprise one or more antennas, and packaged. During further assembly, for example at the manufacturer of smart cards, etc, the antenna can be fixed to the correct position on a carrier.
For the use of antennas, it is often necessary for the ends to be connected to one another by means of a chip. This chip must not make electrical contact with the other turns of the antenna. In a further embodiment of the method according to the invention, the method comprises an additional step of applying an insulator over the metal which has previously been deposited. It is preferable for this insulator to be applied in a subsequent (rotary) screen printing station. The present invention also relates to a method for manufacturing a card with a printed circuit, comprising the steps of screen printing a molten metal or metal alloy onto a substrate in order to form an electrically conductive image, positioning at least one electronic component on the image,
while the electrically conductive material is still liquid, and allowing the assembly formed to cool.
If the image is a path or track on the support, for example made from plastic, of a printed circuit, it is possible, if desired using a suitable temperature control, to delay the solidification of the electrically conductive material, so that it is possible to position the electronic components on the track which has been applied while the conductive material is still liquid or in any event has not yet completely solidified. By (controlled) cooling and solidification of the electrically conductive material, these components are then fixed to the support. In this case, the image functions partially as a conductor and partially as a fixing means. Examples of components of this type include resistors, batteries, capacitors, ICs etc. Fixed connection points can be secured to the ends of an antenna in the same way.