Wireless article including a plural-turn loop antenna

Claim 2

An article comprising: a substrate having two spaced apart holes therethrough; an elongated electrical conductor on one surface of said substrate and having two contacts at the two spaced apart holes of said substrate; a pattern of electrically-conductive adhesive on a second surface of said substrate and extending into the two spaced apart holes, said electrically-conductive adhesive being electrically connected to the two contacts of said elongated electrical conductor through the two spaced apart holes in said substrate and having at least one contact; and an electronic device attached to said substrate and having at least one contact electrically connected to the contact of said pattern of electrically-conductive adhesive.

Claim 3

The article of claim 1 wherein said elongated electrical conductor includes at least one of a deposited electrically-conductive adhesive and a metal foil.

Claim 4

The article of claim 2 wherein said metal foil is laminated to the one surface of said substrate and is patterned to define said elongated electrical conductor.

Claim 5

The article of claim 2 wherein metal is built up on said metal foil within the two spaced apart holes through said substrate.

Claim 6

The article of claim 4 wherein said built-up metal is coated with an oxidation-resistant metal.

Claim 7

The article of claim 2 wherein said elongated electrical conductor includes a spiral conductor having at least one turn.

Claim 8

The article of claim 1 wherein said pattern of electrically-conductive adhesive substantially fills the two spaced apart holes of said substrate to provide electrical connection to said elongated electrical conductor.

Claim 9

The article of claim 1 further including metal built up in the two spaced apart holes on the two contacts of said elongated electrical conductor, wherein said pattern of electrically-conductive adhesive electrically connects to said built up metal.

Claim 10

The article of claim 8 wherein said built-up metal is coated with an oxidation-resistant metal.

Claim 11

The article of claim 1 wherein said pattern of electrically-conductive adhesive is formed by one of roll coating, screen printing, stenciling, mask printing, ink jet printing and laminating an electrically conductive adhesive.

Claim 12

The article of claim 1 wherein said pattern of electrically-conductive adhesive includes a spiral conductor having at least one turn.

Claim 13

The article of claim 1 wherein the at least one contact of said electronic device is electrically connected to the contact of said pattern of electrically conductive adhesive by one of solder and an electrically-conductive adhesive.

Claim 14

The article of claim 12 wherein the electrically-conductive adhesive is deposited with said pattern of electrically-conductive adhesive and of the same electrically-conductive adhesive material.

Claim 15

The article of claim 12 wherein the electronic device is attached to said substrate while the electrically-conductive adhesive is wet.

Claim 16

The article of claim 12 wherein the electronic device is attached to said substrate after the electrically-conductive adhesive is dried or B-staged, and wherein one of said substrate and said electronic device is heated to melt flow said electrically-conductive adhesive.

Claim 17

The article of claim 12 further including a metal coating on at least the contact of the pattern of electrically-conductive adhesive to which said solder connects.

Claim 18

The article of claim 1 wherein said substrate includes one of poly-vinyl-chloride (PVC), polyimide, poly-ethylene terephthallate (PET), polybutylene terephthallate, polyester, polyester terephthallate, polymer blends, polyphynylene sulfide, polysulfone, polyether sulfone, paper film, dried insulating adhesive, and B-staged insulating adhesive.

Claim 19

The article of claim 1 further comprising an insulating adhesive underfill attaching said electronic device to said substrate.

Claim 20

An article comprising: a substrate having at least one hole therethrough; an elongated electrical conductor on one surface of said substrate and having at least one end at the hole of said substrate; a pattern of electrically-conductive adhesive on a second surface of said substrate and extending into the at least one hole, said electrically-conductive adhesive being electrically connected to said elongated electrical conductor through the at least one hole in said substrate and having at least one contact; and an electronic device attached to said substrate and having at least one contact electrically connected to the contact of said pattern of electrically-conductive adhesive, wherein said substrate has at least two second holes in addition to the at least one hole, further comprising a pattern of at least two electrical contacts on the one surface of said substrate, each of said two electrical contacts being at a respective one of the second holes, wherein said electrically-conductive adhesive has at least two additional contacts that are electrically connected to each of said at least two electrical contacts through the at least two second holes, respectively, wherein said electronic device has at least two second contacts electrically connected respectively to the at least two additional contacts of the electrically-conductive adhesive.

Claim 21

An article comprising: a substrate having at least one hole therethrough; an elongated electrical conductor on one surface of said substrate and having at least one end at the hole of said substrate; a pattern of electrically-conductive adhesive on a second surface of said substrate and extending into the at least one hole, said electrically-conductive adhesive being electrically connected to said elongated electrical conductor through the at least one hole in said substrate and having at least one contact; and an electronic device attached to said substrate and having at least one contact electrically connected to the contact of said pattern of electrically-conductive adhesive, wherein said substrate has at least two second holes in addition to the at least one hole, further comprising a pattern of at least two electrical contacts on the one surface of said substrate, each of said two electrical contacts being at a respective one of the second holes, wherein said electrically-conductive adhesive has at least two additional contacts that are electrically connected to each of said at least two electrical contacts through the at least two second holes, respectively, wherein said electronic device has at least two second contacts electrically connected respectively to the at least two additional contacts of the electrically-conductive adhesive.

Claim 22

The article of claim 19 wherein said pattern of electrically-conductive adhesive extends into the at least two second holes of said substrate to provide electrical connection to said two electrical contacts.

Claim 23

The article of claim 19 further including metal built up in each of the two second holes on said two electrical contacts, wherein said pattern of electrically-conductive adhesive electrically connects to said built up metal.

Claim 24

The article of claim 1 further comprising at least one cover layer laminated to said substrate with insulating adhesive.

Claim 25

A wireless article comprising: a substrate having at least first and second spaced apart holes therethrough and having first and second opposing surfaces; an elongated electrical conductor forming a spiral having at least one turn on the first surface of said substrate and having respective first and second terminals respectively located at the first and second spaced apart holes of said substrate; a pattern of electrically-conductive adhesive on the second surface of said substrate defining first and second contacts thereon, said pattern of electrically-conductive adhesive providing respective electrical connections to the first and second terminals of said elongated electrical conductor through the first and second spaced apart holes, respectively, in said substrate; and an electronic device having first and second contacts attached to said substrate, wherein the first and second contacts of said electronic device are electrically connected to the first and second contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 26

A wireless article comprising: a substrate having at least first and second spaced apart holes therethrough and having first and second opposing surfaces; an elongated electrical conductor forming a spiral having at least one turn on the first surface of said substrate and having respective first and second terminals respectively located at the first and second spaced apart holes of said substrate; a pattern of electrically-conductive adhesive on the second surface of said substrate defining first and second contacts thereon, said pattern of electrically-conductive adhesive providing respective electrical connections to the first and second terminals of said elongated electrical conductor through the first and second spaced apart holes, respectively, in said substrate; and an electronic device having first and second contacts attached to said substrate, wherein the first and second contacts of said electronic device are electrically connected to the first and second contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 27

The wireless article of claim 23 wherein said elongated electrical conductor includes at least one of a deposited electrically-conductive adhesive and a metal foil.

Claim 28

The wireless article of claim 24 herein said metal foil is laminated to the first surface of said substrate and is patterned to define said elongated electrical conductor.

Claim 29

The wireless article of claim 24 wherein metal is built up on said metal foil within the first and second spaced apart holes through said substrate.

Claim 30

The wireless article of claim 23 wherein said pattern of electrically-conductive adhesive extends into the first and second holes of said substrate to provide electrical connection to the first and second terminals of said elongated electrical conductor.

Claim 31

The wireless article of claim 23 further including metal built up in the first and second holes on said the first and second terminals, respectively, of said elongated electrical conductor, wherein said pattern of electrically-conductive adhesive provides respective electrical connection to the first and second terminals of said elongated electrical conductor via said built up metal.

Claim 32

The wireless article of claim 23 wherein said pattern of electrically-conductive adhesive is formed by one of roll coating, screen printing, stenciling, mask printing, ink jet printing and laminating an electrically conductive adhesive.

Claim 33

The wireless article of claim 23 wherein said pattern of electrically-conductive adhesive includes a spiral having plural turns.

Claim 34

The wireless article of claim 23 wherein the respective electrical connections of the first and second contacts of said electronic device to the first and second contacts of said pattern of eletctrically conductive adhesive each include one of solder and an electrically-conductive adhesive.

Claim 35

The wireless article of claim 31 further including a metal coating on at least the first and second contacts of the pattern of electrically-conductive adhesive to which said solder connects.

Claim 36

The wireless article of claim 31 wherein the electrical connections of electrically-conductive adhesive are deposited with said pattern of electrically-conductive adhesive and of the same electrically-conductive adhesive material.

Claim 37

The wireless article of claim 31 wherein the electronic device is attached to said substrate while the electrical connections of electrically-conductive adhesive are wet.

Claim 38

The wireless article of claim 31 wherein the electronic device is attached to said substrate after the electrical connections of electrically-conductive adhesive are dried or B-staged, and wherein one of said substrate and said electronic device is heated to melt flow said electrical connections of electrically-conductive adhesive.

Claim 39

The wireless article of claim 23 wherein said substrate includes one of poly-vinyl-chloride (PVC), polyimde, poly-ethylene terephthallate (PET), polybutylene terephthallate, polyester, polyester terephthallate, polymer blends, polyphynylene sulfide, polysulfone, polyether sulfone, paper film, dried insulating thermoplastic adhesive, and B-staged insulating thermosetting adhesive.

Claim 40

The wireless article of claim 23 further comprising an insulating adhesive underfill attaching said electronic device to said substrate.

Claim 41

The wireless article of claim 23 wherein said substrate has at least third and fourth spaced apart holes therethrough, further comprising a pattern of at least first and second electrical contacts on the first surface of said substrate, each of said first and second electrical contacts on the first surface of said substrate being at a respective one of the third and fourth holes, wherein said pattern of electrically-conductive adhesive defines third and fourth contacts on the second surface of said substrate that are electrically connected respectively to said at least first and second electrical contacts on the first surface of said substrate through the third and fourth holes, respectively, and wherein said electronic device has at least third and fourth contacts electrically connected respectively to the at least third and fourth contacts of the pattern of electrically-conductive adhesive.

Claim 42

The wireless article of claim 38 wherein said pattern of electrically-conductive adhesive extends into the at least third and fourth holes of said substrate to provide electrical connection to said first and second electrical contacts.

Claim 43

The wireless article of claim 38 further including metal built up in the third and fourth holes on said first and second electrical contacts, wherein said pattern of electrically-conductive adhesive electrically connects to said built up metal.

Claim 44

The wireless article of claim 23 wherein the first and second contacts of said electronic device are electrically connected respectively to the first and second contacts of said pattern of electrically conductive adhesive by one of solder and an electrically-conductive adhesive.

Claim 45

The wireless article of claim 23 further comprising at least one cover layer laminated to said substrate with insulating adhesive.

Claim 46

A wireless article having a radio frequency antenna comprising: a planar dielectric substrate having at least first and second spaced apart holes therethrough and having first and second opposing surfaces; an elongated electrical conductor on the first surface of said dielectric substrate including a spiral pattern having more than one turn and having first and second terminals respectively located at the first and second spaced apart holes of said dielectric substrate, wherein said elongated electrical conductor is formed of one of a deposited electrically-conductive adhesive and a metal foil; a pattern of electrically-conductive adhesive on the second surface of said dielectric substrate defining first and second contacts thereon, said pattern of electrically-conductive adhesive including a spiral conductor having more than one turn and having first and second terminals wherein the first terminal of the spiral conductor is located at the first spaced apart hole of said dielectric substrate to provide an electrical connection to the first terminal of said elongated electrical conductor through the first spaced apart hole, wherein the second terminal of the spiral conductor connects to the first contact, and wherein the second contact connects to the second terminal of said elongated electrical conductor through the second spaced apart hole; whereby said elongated electrical conductor and said pattern of electrically-conductive adhesive provide the radio frequency antenna; and an electronic device having first and second contacts attached to said dielectric substrate, wherein the first and second contacts of said electronic device are electrically connected to the first and second contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 47

A wireless article having a radio frequency antenna comprising: a planar dielectric substrate having at least first and second spaced apart holes therethrough and having first and second opposing surfaces; an elongated electrical conductor on the first surface of said dielectric substrate including a spiral pattern having more than one turn and having first and second terminals respectively located at the first and second spaced apart holes of said dielectric substrate, wherein said elongated electrical conductor is formed of one of a deposited electrically-conductive adhesive and a metal foil; a pattern of electrically-conductive adhesive on the second surface of said dielectric substrate defining first and second contacts thereon, said pattern of electrically-conductive adhesive including a spiral conductor having more than one turn and having first and second terminals wherein the first terminal of the spiral conductor is located at the first spaced apart hole of said dielectric substrate to provide an electrical connection to the first terminal of said elongated electrical conductor through the first spaced apart hole, wherein the second terminal of the spiral conductor connects to the first contact, and wherein the second contact connects to the second terminal of said elongated electrical conductor through the second spaced apart hole; whereby said elongated electrical conductor and said pattern of electrically-conductive adhesive provide the radio frequency antenna; and an electronic device having first and second contacts attached to said dielectric substrate, wherein the first and second contacts of said electronic device are electrically connected to the first and second contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 48

The wireless article of claim 43 further comprising encapsulating material encapsulating at least said electronic device to said dielectric substrate.

Claim 49

The wireless article of claim 44 wherein said encapsulating material covers at least one of said elongated electrical conductor and said pattern of electrically-conductive adhesive.

Claim 50

The wireless article of claim 44 wherein said dielectric substrate is formed of a flexible material, and wherein said encapsulating material is as least as flexible as said dielectric substrate.

Claim 51

The wireless article of claim 43 wherein said wireless article is employed as one of an identification tag, an identification badge, an access card, a credit card, a debit card, a cash card and phone card.

Claim 52

The wireless article of claim 43 further comprising a pattern of at least two external contacts on the first surface of said dielectric substrate located at third and fourth spaced apart holes through said dielectric substrate, wherein said electronic device has third and fourth contacts attached to said dielectric substrate, wherein the third and fourth contacts of said electronic device are electrically connected respectively to the at least two external contacts, respectively, of said pattern of external contacts.

Claim 53

The wireless article of claim 43 wherein said dielectric substrate is formed of a flexible material, and wherein said electrically-conductive adhesive is as least as flexible as said dielectric substrate.

Claim 54

The wireless article of claim 43 further comprising at least one additional electronic device having first and second contacts attached to said dielectric substrate, wherein the first and second contacts of said at least one additional electronic device are electrically connected to corresponding contacts of said pattern of electrically-conductive adhesive.

Claim 57

The method of claim 51 wherein said providing a substrate comprises laminating a metal foil and a sheet of substrate material, and patterning the metal foil to form the elongated conductor.

Claim 58

The method of claim 51 wherein said providing a substrate comprises depositing a substrate material onto a metal foil, forming first and second holes in the substrate material, and patterning the metal foil to form the elongated conductor.

Claim 59

The method of claim 53 including one of drying, B-staging and curing the substrate material prior to said patterning the metal foil.

Claim 60

The method of claim 53 wherein said depositing a substrate material includes depositing an insulating adhesive by one of roll coating, screen printing, stenciling, mask printing, ink jet printing and laminating.

Claim 61

The method of claim 51 wherein said providing a substrate comprises depositing an elongated conductor on the first surface a sheet of substrate material.

Claim 62

The method of claim 56 wherein said depositing an elongated conductor includes depositing a pattern of an electrically-conductive adhesive by one of roll coating, screen printing, stenciling, mask printing, and ink jet printing.

Claim 63

The method of claim 51 wherein said depositing electrically-conductive material comprises building up metal in the holes on the terminals of the elongated conductor extending over the holes.

Claim 64

The method of claim 51 wherein said depositing electrically-conductive material comprises depositing electrically-conductive adhesive into the holes through the substrate contacting the terminals of the elongated conductor extending over the holes.

Claim 65

The method of claim 51 wherein said depositing a pattern of electrically conductive adhesive includes one of roll coating, screen printing, stenciling, mask printing, and ink jet printing.

Claim 66

The method of claim 51 wherein said attaching comprises connecting the respective contacts of the electronic device and of the pattern of electrically-conductive adhesive while the electrically-conductive adhesive is wet.

Claim 67

The method of claim 51 wherein said attaching comprises drying or B-staging the pattern of electrically-conductive adhesive, heating one of the substrate and electronic device to a melt flow temperature of the electrically-conductive adhesive, and connecting the respective contacts of the electronic device and of the pattern of electrically-conductive adhesive.

Claim 68

The method of claim 51 wherein said attaching comprises coating a metal on at least the first and second contacts of the pattern of electrically-conductive adhesive, heating one of the substrate and electronic device to a melt flow temperature of solder, and connecting with solder the respective contacts of the electronic device and of the pattern of electrically-conductive adhesive.

Claim 71

The method of claim 64 wherein said providing a substrate comprises laminating a metal foil and a sheet of substrate material, and patterning the metal foil to form the elongated conductor.

Claim 72

The method of claim 64 wherein said providing a substrate comprises depositing a substrate material onto a metal foil, forming the two spaced apart holes in the substrate material, and patterning the metal foil to form the elongated conductor.

Claim 73

The method of claim 66 including one of drying, B-staging and curing the substrate material prior to said patterning the metal foil.

Claim 74

The method of claim 66 wherein said depositing a substrate material includes depositing an insulating adhesive by one of roll coating, screen printing, stenciling, mask printing, ink jet printing and laminating.

Claim 75

The method of claim 64 wherein said providing a substrate comprises depositing an elongated conductor on the first surface a sheet of substrate material.

Claim 76

The method of claim 69 wherein said depositing an elongated conductor includes depositing a pattern of an electrically-conductive adhesive by one of roll coating, screen printing, stenciling, mask printing, and ink jet printing.

Claim 77

The method of claim 64 further comprising depositing electrically-conductive metal in the two spaced apart holes on the two terminals of the elongated conductor extending over the two spaced apart holes.

Claim 78

The method of claim 64 wherein said depositing electrically-conductive adhesive comprises depositing electrically-conductive adhesive into and substantially filling the two spaced apart holes through the substrate contacting the two terminals of the elongated conductor extending over the two spaced apart holes.

Claim 79

The method of claim 64 wherein said depositing a pattern of electrically conductive adhesive includes one of roll coating, screen printing, stenciling, mask printing, and ink jet printing.

Claim 80

The method of claim 64 wherein said attaching comprises connecting the at least one contact of the electronic device and of the pattern of electrically-conductive adhesive while the electrically-conductive adhesive is wet.

Claim 81

The method of claim 64 wherein said attaching comprises drying or B-staging the pattern of electrically-conductive adhesive, heating one of the substrate and electronic device to a melt flow temperature of the electrically-conductive adhesive, and connecting the respective at least one contact of the electronic device and of the pattern of electrically-conductive adhesive.

Claim 82

The method of claim 64 wherein said attaching comprises coating a metal on at least the at least one contact of the pattern of electrically-conductive adhesive, heating one of the substrate and electronic device to a melt flow temperature of solder, and connecting with solder the respective at least one contact of the electronic device and of the pattern of electrically-conductive adhesive.

Claim 83

A combination contact and wireless article comprising: a substrate having first and second opposed surfaces and having at least first, second and third spaced-apart holes therethrough; an elongated electrical conductor providing an antenna on the first surface of said substrate and having at least one terminal at the first hole through said substrate; a pattern of at least two electrical contacts on the first surface of said substrate, each of said two electrical contacts being at a one of the second and third holes through said substrate; a pattern of electrically-conductive adhesive on the second surface of said substrate, said pattern of electrically-conductive adhesive defining first, second and third contacts that are electrically connected to said elongated electrical conductor and said two electrical contacts through the first, second and third holes, respectively, through said substrate; and an electronic device attached to the second surface of said substrate and having at least three contacts electrically connected to the first, second and third contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 84

A combination contact and wireless article comprising: a substrate having first and second opposed surfaces and having at least first, second and third spaced-apart holes therethrough; an elongated electrical conductor providing an antenna on the first surface of said substrate and having at least one terminal at the first hole through said substrate; a pattern of at least two electrical contacts on the first surface of said substrate, each of said two electrical contacts being at a one of the second and third holes through said substrate; a pattern of electrically-conductive adhesive on the second surface of said substrate, said pattern of electrically-conductive adhesive defining first, second and third contacts that are electrically connected to said elongated electrical conductor and said two electrical contacts through the first, second and third holes, respectively, through said substrate; and an electronic device attached to the second surface of said substrate and having at least three contacts electrically connected to the first, second and third contacts, respectively, of said pattern of electrically-conductive adhesive.

Claim 85

A wireless article comprising: a substrate having at least one hole therethrough; an elongated electrical conductor forming an antenna on one surface of said substrate and having a terminal at the at least one hole of said substrate; a pattern of electrically-conductive adhesive on a second surface of said substrate and extending into the at least one hole, said electrically-conductive adhesive being electrically connected to the terminal of said elongated electrical conductor through the at least one hole in said substrate, and said electrically-conductive adhesive defining at least one contact on the second surface of said substrate; and a flip-chip electronic device attached to the second surface of said substrate in a flip-chip manner, said flip-chip electronic device having at least one contact facing the second surface of said substrate and electrically connected to the contact of said pattern of electrically-conductive adhesive on the second surface of said substrate.

Claim 86

A wireless article comprising: a substrate having at least one hole therethrough; an elongated electrical conductor forming an antenna on one surface of said substrate and having a terminal at the at least one hole of said substrate; a pattern of electrically-conductive adhesive on a second surface of said substrate and extending into the at least one hole, said electrically-conductive adhesive being electrically connected to the terminal of said elongated electrical conductor through the at least one hole in said substrate, and said electrically-conductive adhesive defining at least one contact on the second surface of said substrate; and a flip-chip electronic device attached to the second surface of said substrate in a flip-chip manner, said flip-chip electronic device having at least one contact facing the second surface of said substrate and electrically connected to the contact of said pattern of electrically-conductive adhesive on the second surface of said substrate.