Method for assembling components and antennae in radio frequency identification devices

An RFID device comprising:

• a first electrical component having
• a first electrically conductive contact;
• a second electrical component having
• a second electrically conductive contact;
• wherein the first and second electrically conductive contacts are in alignment with one another
• at least one electrically conductive hard particle attached to at least one of the first and second electrically conductive contacts,
• wherein the at least one electrically conductive hard particle has a hardness at least as great as that of at least one of the first and second electrically conductive contacts;
• a non-conductive adhesive disposed between the first and second electrically conductive contacts;
• wherein the first and second electrically conductive contacts are held together by the non-conductive adhesive once the adhesive cures;
• wherein a permanent electrical connection is formed between the first and second electrically conductive contacts;
• and
• wherein a permanent physical attachment is formed between the first electrical component and the second electrical component.

A method for making a plurality of electrical components for RFID devices, each of the plurality of electrical components having a first electrically conductive contact, each of the plurality of electrical components for physically and electrically connecting to an additional electrical component in an RFID device, the additional electrical component having a second electrically conductive contact that forms an electrical connection with the first electrically conductive contact, the method comprising:

• providing the plurality of electrical components in an array;
• attaching at least one electrically conductive hard particle to the first electrically conductive contact on each of the plurality of electrical components,
• wherein the at least one electrically conductive hard particle has a hardness at least as great as that of at the second electrically conductive contact;
• and
• separating each of the plurality of electrical components from the array.

An electrical component for use in an RFID device, the electrical component for physically and electrically connecting to an additional electrical component in the RFID device, the additional electrical component having a second electrically conductive contact that forms an electrical connection with the first electrically conductive contact, the electrical component comprising:

• a component base, the component base further comprising
• a first electrically conductive contact for forming an electrical connection with a second electrically conductive contact on the additional electrical component;
• and
• at least one electrically conductive hard particle attached to the first electrically conductive contact,
• wherein the at least one electrically conductive hard particle has a hardness at least as great as that of the second electrically conductive contact.

A method for permanently physically and electrically attaching an electrical component having a first electrically conductive contact to an electrically conductive area on a substrate, the method comprising:

• attaching at least one electrically conductive hard particle to at least one of the electrically conductive contact and a contact area of the electrically conductive area,
• wherein the at least one electrically conductive hard particle has a hardness at least as great as that of at least one of the electrically conductive contact and the contact area;
• placing a non-conductive adhesive between the electrically conductive contact and the contact area;
• placing the electrically conductive contact in alignment with the contact area;
• applying pressure to hold the electrically conductive contact and the contact area together;
• and
• curing the non-conductive adhesive,
• thereby creating a permanent electrical connection between the electrically conductive contact and the contact area, and
• permanently physically attaching the electrical component to the electrically conductive area.