As a key component of the RFID (Radio Frequency Identification) system, smart labels represent one of the most advanced non-contact sensing technologies. They offer numerous advantages, including large data storage capacity, high data density, strong resistance to pollution and environmental damage, excellent durability, long reading distance, fast data transfer speed, and robust data security. These features make them highly suitable for various applications. As RFID technology and material science continue to advance, smart labels are expected to gradually replace traditional barcodes, becoming the preferred choice in retail, packaging, and logistics industries.
RFID is a non-contact automatic identification technology that enables the automatic recognition of objects and the retrieval of relevant data through radio frequency signals. An RFID system typically consists of three main components: a smart tag, a reader, and an RF antenna, as illustrated in Figure 1. The process works as follows: when the tag enters the RF field generated by the reader, it receives the signal, which induces a current in its internal circuit, activating the chip. The chip then transmits the stored information via the tag’s built-in antenna. The RFID antenna captures this signal and sends it to the reader, where it is demodulated and decoded to extract the data.
One of the major benefits of RFID technology is its ability to read multiple tags simultaneously without any manual intervention. This makes it ideal for use in environments such as supermarkets, where items with smart labels can be quickly scanned as they pass through the RF zone, significantly improving efficiency and reducing labor costs. This not only streamlines the checkout process but also enhances the customer experience by saving time and effort.
Despite its many advantages, the widespread adoption of smart labels is currently limited by their relatively high cost. Market research indicates that the price per label ranges from approximately 20 cents to $1, while most consumers consider a price of around 5 cents acceptable for a single item. To promote the adoption of smart labels, efforts should focus on both improving their performance and reducing production costs.
A smart tag typically consists of a silicon chip, an embedded antenna (coil), and a substrate, as shown in Figure 3. While the cost and performance of the chip and substrate are relatively stable, the main opportunities for improvement lie in optimizing the manufacturing process of the internal antenna. When evaluating the functionality and cost-effectiveness of a particular antenna design, at least three criteria must be met: first, the antenna should have good electrical performance (such as proper impedance); second, it should allow for easy mounting of the chip; and third, it should support high-volume, low-cost production.
Currently, there are three primary methods used to manufacture RFID tag antennas:
· The etching method, also known as subtractive manufacturing. It involves laminating copper foil onto a plastic film, coating it with photoresist, exposing it to light, and then using chemical etching to remove the excess copper, leaving behind the desired coil pattern.
· The coil winding method. In this approach, the antenna coil is wound around a tool and fixed in place. This technique is commonly used for low-frequency tags (typically below 135 kHz) where cost is less of a concern.
· The conductive ink printing method, also known as additive manufacturing. This method uses printed conductive ink to create the antenna on a flexible or rigid substrate. Screen printing is the most common technique for producing UHF RFID tags.
Advantages of screen-printed tag antennas
Screen-printed antennas use conductive ink, a composite material made by dispersing metal particles (such as silver, copper, or carbon) in a binder. Once printed on a substrate, the ink acts as a conductor, forming an antenna that can receive RFID-specific RF signals. Compared to other methods like copper etching, screen-printed antennas offer several advantages, making them a green, stable, and cost-effective solution, especially for mass production.
1. Low Cost
One of the most significant benefits of using screen-printed conductive ink for internal antennas is the low cost and ease of operation. This cost advantage is evident in two aspects:
(1) Screen printing process. The initial investment required for screen printing equipment is much lower than that for copper etching systems. Additionally, since the screen printing process does not require special environmental controls, the maintenance and operational costs are generally lower than those of copper etching. In fact, maintaining a copper etching line and managing waste (such as chemical residues) involves high fixed costs, which ultimately increase the per-unit cost of the label.
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