# US 2020/0403291 A1 · Foil Laminate Intermediate and Method of Manufacturing

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- Number: US 2020/0403291 A1
- Document ID: US20200403291A1
- Status: Published application
- Kind: A1
- Application number: 17/013,470
- Filed: 2020-09-04
- Published: 2020-12-24
- Earliest claimed: 2010-06-14
- Assignees: Avery Dennison Retail Information Services LLC
- Applicants: Avery Dennison Retail Information Services, LLC
- Inventors: Ian J. FORSTER; Peter COCKERELL; Norman HOWARD
- Web page: https://patentgrep.com/patent/US20200403291A1

## CPC

- H01P 11/003: {Manufacturing lines with conductors on a substrate, e.g. strip lines, slot lines}
- B23K 26/364: for making a groove or trench, e.g. for scribing a break initiation groove
- B32B 38/10: Removing layers, or parts of layers, mechanically or chemically
- G06K 19/0723: {the record carrier comprising an arrangement for non-contact communication, e.g. wireless communication circuits on transponder cards, non-contact smart cards or RFIDs}
- G06K 19/07718: {the record carrier being manufactured in a continuous process, e.g. using endless rolls}
- G06K 19/07749: {the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card}
- G06K 19/0775: {arrangements for connecting the integrated circuit to the antenna}
- G06K 19/07754: {the connection being galvanic}
- G06K 19/07786: {the antenna being of the HF type, such as a dipole}
- B32B 37/12: characterised by using adhesives
- B32B 38/145: {Printing}
- B32B 2305/10: Fibres of continuous length
- B32B 2307/302: Conductive
- B32B 2317/12: Paper, e.g. cardboard
- B32B 2519/02: RFID tags
- Y10T 29/49016: Antenna or wave energy "plumbing" making
- Y10T 29/49018: with other electrical component
- Y10T 29/49117: Conductor or circuit manufacturing
- Y10T 29/49156: with selective destruction of conductive paths
- Y10T 29/5317: Laminated device
- Y10T 29/53174: Means to fasten electrical component to wiring board, base, or substrate
- Y10T 156/1052: with cutting, punching, tearing or severing
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T 428/24917: including metal layer
- Y10T 428/2809: including irradiated or wave energy treated component
- Y10T 428/2817: Heat sealable
- H01P: WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE (operating at optical frequencies G02B)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- G06K: GRAPHICAL DATA READING (image or video recognition or understanding G06V); PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention relates to a method of manufacturing a metal foil laminate which may be used for example to produce an antenna for a radio frequency (RFID) tag, electronic circuit, photovoltaic module or the like. A web of material is provided to at least one cutting station in which a first pattern is generated in the web of material. A further cutting may occur to create additional modifications in order to provide additional features for the intended end use of the product. The cutting may be performed by a laser either alone or in combinations with other cutting technologies.

## Claims

### Claim 1

A method of making a metal foil laminate in a roll to roll process comprising;
providing a first web of material in a continuous format;
applying a pattern of adhesive to a first face of the first web of material;
providing a second web of conductive material;
positioning the second web of conductive material over the pattern of adhesive to form a foil laminate;
cutting the foil laminate at a first cutting station to form an intermediate shape,
advancing the foil laminate having the intermediate shape to a second cutting station;
cutting the intermediate shape to form a finished structure which includes an opening to receive an integrated circuit.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first cutting station comprises a laser.

### Claim 3 (depends on 1)

The method of claim 1, wherein the second cutting station comprises a laser.

### Claim 4

A method of making a conductive metal foil laminate, comprising the steps of:
providing a substrate having first and second sides;
applying an adhesive pattern to the first side of the substrate;
providing a metal foil having first and second sides such that the second side of the foil is in contact with the adhesive;
cutting a first pattern in the metal foil coincident with the adhesive pattern to create a first conductive foil pattern and a matrix; and
removing the matrix from the first conductive foil pattern.

### Claim 5 (depends on 4)

The method as recited in claim 4, wherein the adhesive includes an optical brightener.

### Claim 6 (depends on 4)

The method as recited in claim 4, wherein a second pattern is cut in the metal foil to create a second conductive foil pattern coincident with the first pattern.

### Claim 7 (depends on 4)

The method as recited in claim 4, including a further step of removing a matrix after cutting of the second pattern.

### Claim 8 (depends on 4)

The method as recited in claim 4, wherein the cutting of the first and second pattern is accomplished by a laser.

### Claim 9 (depends on 4)

The method as recited in claim 4, including a further step of deadening portions of the adhesive in areas outside of the first and second patterns in the metal foils after the step of applying the adhesive.

### Claim 10 (depends on 4)

The method of claim 4, wherein first and second patterns are used in at least one of a radio frequency identification device, photovoltaic module or electronic circuit.

### Claim 11

A method of making a conductive pattern, comprising the steps of:
providing a metal foil laminate, the metal foil laminate having a foil layer, an adhesive layer beneath the foil layer and a substrate beneath the adhesive layer;
making a first cut in the metal foil laminate, through the foil layer to create a first conductive pattern;
allowing energy/weakness in the metal foil laminate to dissipate; and
providing a second cut in the metal foil laminate to create a second conductive pattern only in the foil layer, the second conductive pattern being distinct from the first pattern.

### Claim 12 (depends on 11)

The method of claim 11, wherein optical brighteners are provided in the layer of adhesive in a pattern corresponding to the first and second patterns in the foil layer.

### Claim 13 (depends on 11)

The method of claim 11, wherein the cuts are performed by laser cutting using an ytterbium laser.

### Claim 14 (depends on 11)

The method of claim 11, wherein the first and second cuts only occur in the foil layer and do not impact the adhesive layer or substrate.

### Claim 15 (depends on 11)

The method of claim 11, including a further step of deadening the adhesive in areas outside the first and second conductive patterns in the foil layer after the step of providing a metal foil laminate.

### Claim 16 (depends on 11)

The method of claim 11, wherein first and second patterns are used in at least one of a radio frequency identification device, photovoltaic module or electronic circuit.

### Claim 17

A web of foil laminate intermediate assemblies, comprising:
a web that includes a substrate having first and second sides;
a plurality of foil laminate intermediates provided on the web;
the substrate having first and second faces the substrate having a plurality of registration marks along at least one of the first and second sides;
a pattern of adhesive disposed on the first face of the substrate and adjacent the plurality of registration marks, wherein the plurality of registration marks are each provided with an optical brightener within each registration mark and at least one foil laminate intermediate is aligned with at least one of the plurality of registration marks such that each of the plurality of foil laminate intermediates do not cover the plurality of registration marks;
a metal foil applied over the pattern of adhesive; and
the metal foil having at least a first pattern with the at least first pattern corresponding to the pattern of adhesive.

### Claim 18 (depends on 17)

The web as recited in claim 17, wherein the first pattern is an antenna pattern for a radio frequency identification device.