As the core component of an RFID (Radio Frequency Identification) system, smart labels represent one of the most advanced non-contact sensing technologies. These tags offer a range of significant advantages, including large data storage capacity, high data density, strong resistance to pollution, excellent durability, and minimal impact from water, oil, or chemical exposure. They also provide long reading distances, fast read speeds, and robust data security. With continuous advancements in RFID technology and materials science, smart labels are gradually replacing traditional barcodes and are becoming increasingly popular in retail, packaging, and logistics sectors.
RFID is a contactless automatic identification technology that enables the automatic recognition of objects and the collection of related 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 operation process works as follows: when the tag enters the RF field generated by the reader, the antenna on the reader sends out a signal that powers the tag’s internal circuit. This activates the chip inside, which then transmits the stored information back to the reader via its built-in antenna. The reader receives the signal, demodulates it, and decodes the data for further use.
One of the key benefits of RFID technology is its ability to read multiple smart tags simultaneously without any manual intervention. This makes it ideal for applications where efficiency and speed are critical, such as in supermarkets or warehouses. By simply passing items with smart tags through the RF zone, the system can automatically identify and track them, significantly reducing labor costs and improving overall operational efficiency. This not only benefits businesses but also enhances the shopping experience for consumers by saving time and effort.
Despite their many advantages, smart labels still face challenges, particularly in terms of cost. Currently, the price per label ranges from about 20 cents to $1, while industry experts believe that for individual products, a label should ideally cost no more than 5 cents. Therefore, the future development of smart labels should focus on two main areas: enhancing their performance and lowering production costs. Improving the manufacturing process of the internal antenna is one of the most effective ways to achieve this goal.
A smart tag generally consists of a silicon chip, an internal antenna (coil), and a substrate, as shown in Figure 3. While the cost and performance of the chip and substrate are relatively stable, the real potential for cost reduction lies in optimizing the antenna manufacturing process. To evaluate the effectiveness of a particular antenna manufacturing method, at least three criteria must be met: 1) the antenna must have good electrical performance, such as optimal impedance; 2) it should allow for easy integration with the chip; and 3) it must support mass production at low cost.
There are currently three primary methods used to manufacture RFID tag antennas:
· The etching method, also known as subtractive manufacturing. This involves laminating a copper foil onto a plastic film, applying a photoresist layer, exposing it to light through a patterned mask, and then using a chemical etchant to remove the exposed copper, leaving behind the desired coil shape.
· The coil winding method. In this approach, the antenna coil is wound around a mandrel and fixed in place. This technique is commonly used for low-frequency tags (typically below 135 kHz) and is often chosen when cost is not the primary concern.
· The conductive ink printing method, also referred to as additive manufacturing. This technique involves printing a conductive ink—made up of metal particles like silver, copper, or carbon dispersed in a binder—onto a flexible or rigid substrate. This method is widely used for UHF RFID tags and offers several advantages over traditional methods.
Screen printing of conductive ink for RFID tag antennas has become a popular choice due to its numerous benefits. Conductive ink acts as a conductor, forming circuits, antennas, and resistors after being printed on a substrate. It can be applied to various materials such as paper, PVC, or PE, making it highly versatile. Compared to other methods like copper etching, screen-printed antennas offer a more environmentally friendly, stable, and cost-effective solution, especially for large-scale production.
One of the most significant advantages of using screen printing with conductive ink is its low cost. This method is both economical and easy to implement. The cost savings come from two main factors: first, the initial investment in screen printing equipment is much lower than that required for copper etching systems. Second, the maintenance and operational costs of screen printing are also lower, as it does not involve the same environmental regulations or waste management issues as chemical etching. In fact, managing a copper etching line and disposing of chemical waste can be very expensive, increasing the overall cost of each label.
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