Printed antennas with variable conductive ink layer thickness J. Sidén, M.K. Fein, A. Koptyug and H.-E. Nilsson Abstract: One of the complex tasks in mass production of RF electronics is printing the communication antenna using electrically conductive ink. For example, this is very common for radiofrequency identification (RFID) tags. Electrical properties of the ink are mostly determined by conductive (e.g. silver) particles mixed into the ink solution and the way they ‘connect’ in the cured ink. It is also desirable to minimise the amount of ink used per antenna, because high-conducting metals like silver used in the ink are rather expensive. Metal-based inks have limited conductivity, so the thicker the cured ink layer will be the better the antenna radiation efficiency can be achieved, but also the higher will be the costs. In the paper, the authors report on the investigations of the possibility of minimising the amount of ink used per antenna. This can be achieved by printing thicker ink layers, where antenna structures are known to have high current density. Two common antenna structures and a dedicated antenna for passive RFID are used in the investigation. The main result of the paper is that radiation efficiency depends primarily on the total amount of ink used for printing the antenna, rather than on the variations of the layer thickness within the antenna structure. 1 Introduction Printed electronics is a relatively new area of research and development targeting electronics manufacturing using adapted commercial printing presses [1]. When the technology matures it will have a capacity to deliver very large amounts of printed electronic units at a very favourable price, as compared to the traditional silicon-based technology [2, 3]. Printed-radio-frequency-identification (RFID) tags [4] and wireless sensor nodes [5] are assumed to be among the key applications that could benefit from the organic electronics developments. While the semiconductor elements in RFID tags are likely to stay silicon-based for quite some time, the communicating antennas are already printed utilising commercially available techniques and electrically conductive ink. Three-dimensional antenna structures such as horn antennas can also be synthesised directly from CAD files using rapidly deposited two-dimensional layers of polymers [6]. Commonly, metallic particles shaped as flakes are blended into an ink, which is applied on a substrate with a flexographic printer. In the dried ink, the metal particles touch and overlap, creating continuous conductive traces. There is a large potential of cheap bulk antenna fabrication using printed conductor technology. However, ink-trace conductors have at least two major drawbacks. First, their conductivity is still not as good as that of corresponding # The Institution of Engineering and Technology 2007 doi:10.1049/iet-map:20060021 Paper first received 8th February and in revised form 28th May 2006 J. Sidén and H.-E. Nilsson are with Mid-Sweden University, Electronics Design Division, Sundsvall 85170, Sweden M.K. Fein is with Precisia, LLC, 4600 Arrowhead Dr., Ann Arbor, MI 48108, USA A. Koptyug is with Sensible Solutions Sweden AB, Universitetsallén 32, Sundsvall 85171, Sweden E-mail: [email protected] IET Microw. Antennas Propag., 2007, 1, (2), pp. 401– 407 solid metal traces. Despite the fact that there is less metal in the ink-based conductor, as compared to the solid metal one (such as etched copper), they are still rather expensive. It happens because the best conductive inks use silver or silver-coated particles blended into them, and the price of silver and the manufacturing costs of silver powder and silver flakes are rather high. The abovementioned drawbacks result in a contradictory demand to the antenna printing: thicker ink layers would be preferable for high radiation efficiency and thinner ink would be desirable for keeping production costs at a minimum. Basic laws of conductivity for homogeneous media state that ohmic losses decrease as conductor cross-section increases [7]. Although printed ink traces are not homogenous, similar behaviour can also be applied in this case. Total resistance of the printed electrical conductor with a fixed trace width will have its resistance proportional to the overall trace length and be inversely proportional to the ink-layer thickness. Similarly, a printed antenna will experience certain high-frequency resistivity influencing its input impedance and radiation efficiency showing a dependence on the ink-layer thickness and, possibly, layer thickness variations throughout the structure. Radiation efficiency of antennas is a crucial factor in passive RFID tags because the RFID chip acquires all its power from the electromagnetic wave of an interrogating RFID unit [8]. Small radiation efficiency of the tag antenna immediately results in a low reading range of the RFID tag. Already, it has been studied how the ink thickness affects Q-values for low frequency RFID antennas (i.e. printed inductive coils) [9 – 12] and how it affects the radiation efficiency of RFID antennas working in the UHF band [13 – 15]. It has also been shown how the total printed area can be minimised by using gridded antenna patterns [16]. This paper reports on investigating possible benefits of a variable ink-layer thickness approach. In this approach, antenna pattern areas with highest current density are identified and printed with thicker ink layers. We compare the 401 results of computer modelling with experiment for two common antenna structures. We also characterise the influence of the variable-layer-thickness tag-antenna printing on the maximum reading range for a commercial RFID system. Parameters for all printed antennas are also compared to the ones of the solid copper-based antennas with the same pattern. In the computer simulations, reference structures of copper are assumed to be made of perfect electric conductor (PEC). Investigations were carried out for the structures working at 868 MHz, one of the ISM bands for nonlicensed lowpower transmitting systems available within the EU [17]. The corresponding band allowed for such applications in the USA is 902 – 928 MHz [18]. Although additional tests must be conducted to specify antenna performance at 902 – 928 MHz, we expect that qualitative conclusions could be directly extended from the mentioned EU band to the US band. 2 Printed dipole and bow-tie antennas with different sheet resistance of conductors We have investigated the efficiency of different printing approaches for two antenna structures, namely the halfwavelength dipole and the bow tie, as illustrated in Figs. 1 and 2 and Figs. 3 and 4, respectively. The choice of antennas represents one structure with relatively small area and constant width throughout the antenna length, the half-wavelength dipole. The other antenna, the bow tie represents a structure with relatively large area and increasing width seen from the antenna centre. Fig. 1 illustrates the current distribution in the dipole antenna with the dimensions close to a half wavelength. For the chosen frequency of 868 MHz the dipole antenna dimensions were structure length ld ¼ 163 mm and trace width w ¼ 2 mm. Fig. 3 illustrates the current distribution in the bow-tie antenna, as presented when modelled using electromagnetic simulation software package Ansoft HFSS 9.2. The textured pattern is due to triangular meshing, and the darker a triangle is the higher the current density is in that area. The antenna dimensions for the 868 MHz bow tie were structure length lb ¼ 124 mm and flare angle a ¼ 308. Test dipole and bow-tie antennas were manufactured with ink layers of different thickness using a flexographic printer, resulting in different sheet resistance of conducting layers. The variable ink thickness approach is illustrated in Figs. 2 and 4, where variations in ink-layer thickness were Fig. 3 Ink pattern for half-wavelength dipole antenna structure printed with thicker ink layer in the areas with highest current density achieved by using different anilox rollers and by adding consecutive extra layers of paint at specific antenna areas. Efficiency of the printed antennas was characterised by measuring transmitted power in a set-up with a reference antenna and an antenna under test placed at one metre distance in a wooden (balsa) fixture. The transmission parameter for transmission from the reference antenna to the antenna under test is further denoted as S21 and is measured using the Network Analyser E8364 (PNA Series) by Agilent Technologies. Table 1 presents the comparison of the simulated and measured transmission efficiency for the structures printed with different layer thickness. Values are presented as test antenna radiation efficiency and are normalised to the power supplied to the reference, copper antennas. The simulated radiation efficiency is acquired by using the Ansoft HFSS EM modelling software package, where the antennas are regarded as twodimensional structures with the sheet impedance corresponding to the one of the test structures. The relative amount of used ink is calculated from the measurements of thickness of printed traces and normalised to the thickest trace used for each investigated antenna. In present prints thickest trace tops were about 15– 20 mm, giving a sheet resistance of about 50 mV/square. A theoretical assumption that conductor sheet resistance is inversely proportional to ink-layer thickness was found to be good with relatively thick ink layers and relatively wide conductive traces. With the thin layers, measured conductivity was, however, commonly lower than predicted. In the case of cured ink layers thicker than 10 mm measured conductivity was very close to an expected 1 106 S/m. At the same time, conductivity values down to 2 105 S/m were measured for the layers of about 2 – 4 mm. Most probably, this is due to the fact that metal flakes responsible for the conductivity of the ink are, in turn, several micrometres in size. With the ink-layer thickness close to the average metal particle size, the amount of continuous conductive ‘bridges’ with overlapping metal particles ‘connected in parallel’ becomes significantly smaller. And one can also expect that the ‘overlapping area’ between two adjacent flakes in such a bridge, responsible for the resistance of Fig. 1 Current distribution in the half-wavelength dipole antenna Fig. 2 Computer simulated current density distribution with triangular meshing for a bow-tie antenna (darker areas correspond to higher current density) 402 Fig. 4 Ink pattern for bow-tie antenna structure printed with thicker ink layer in the areas with highest current density IET Microw. Antennas Propag., Vol. 1, No. 2, April 2007 Table 1: Radiation efficiency for printed antennas with different conductor sheet resistance Dipole antenna Sheet resistance Simulated radiation Total structure: Total structure: Total structure: Inner one third: Inner one third: Inner one third: 2395 mV/sq 238 mV/sq 51 mV/sq 103 mV/sq 60 mV/sq 52 mV/sq Outer two thirds: Outer two thirds: Outer two thirds: 6720 mV/sq 1012 mV/sq 213 mV/sq 38% 81% 95% 34% 73% 89% 29% 78% 93% 32% 57% 83% 21% 40% 100% 31% 48% 45% 1.4 mm3 2.7 mm3 6.6 mm3 2.1 mm3 3.2 mm3 3.0 mm3 Total structure: Total structure: Total structure: Inner one third: Inner one third: Inner one third: 3242 mV/sq 178 mV/sq 54 mV/sq 86 mV/sq 41 mV/sq 35 mV/sq Outer two thirds: Outer two thirds: Outer two thirds: 1097 mV/sq 1154 mV/sq 211 mV/sq efficiency Measured radiation efficiency Relative amount of ink used Total amount of ink used (Cured Vol.) Bow-tie antenna Sheet resistance Simulated radiation 58% 95% 98% 92% 92% 97% 54% 81% 93% 87% 76% 89% 18% 44% 100% 21% 33% 47% 7.4 mm3 18 mm3 41 mm3 8.6 mm3 14 mm3 19 mm3 efficiency Measured radiation efficiency Relative amount of ink used Total amount of ink used (Cured Vol.) the flake-to-flake contact in such a bridge, also becomes higher. It was also found that thin conductive ink layers suffer from common problems known in flexographic printing as lining and the producing of a halo effect by squeezing ink out at the edges of printed features. With the lining, solid ink layers turn into a set of small narrow lines in the direction of the print, creating significant anisotropy in conductivity (and sheet resistance). For thin layers anisotropy of about 2mm was observed, i.e. the conductivity in the print direction was twice higher than the one in the perpendicular direction. Thicker layers introduced a lower level of anisotropy but still present at about 1.2 – 1.5. All manufactured antennas were printed in the direction of their length and all sheet resistances were also measured in this direction. The first three columns in Table 1 refer to the antennas printed with the uniform ink thickness and sheet resistance all over the structure. Theoretically, using twice smaller amount of ink should yield twice higher conductor sheet resistance and vice versa. The last three columns in Table 1 refer to the antennas printed with the ink thickness lower at the periphery of the antenna and higher at the areas with maximum current density. Figs. 5a and b gives an additional and more visual view of the results presented in Table 1. As mentioned here, for relatively thin flexographically printed layers, the proportionality of the trace conductivity to the layer thickness (amount of ink used for the fixed pattern) does not hold. For example, decreasing the amount of ink used for printing the dipole by almost half, from 40 to 21%, was causing tenfold change in the sheet resistance instead of doubling it. Illustrations of IET Microw. Antennas Propag., Vol. 1, No. 2, April 2007 corresponding cured ink traces are given in Figs. 6 – 9. The topography maps were acquired using an FRT laser optical profilometer and reveal the roughness of the conductor surface (i.e. significant variation in the layer thickness) for the very thin traces and significant effects of squeezed out ink is seen at trace edges. Table 1 clearly illustrates that using printed structures with thick ink traces and low sheet resistance results in better antenna parameters. Also it should be noted that changing the layer thickness more than two times, from 100 ink to 40% ink, when manufacturing the thick ink layer dipole antenna, measured radiation efficiency only drops from 93 to 78% as compared to the perfect conductor case. The same effect stays for the bow-tie antenna. A level of 100% ink is a normalised value for each antenna structure’s thickest print, but the total pattern surface area for the bow-tie antenna is significantly larger than for the dipole one working at the same frequency. If the cost saving is the dominating design issue, the obvious choice should be the dipole antenna, simply because of its smaller total area. However, ordinary thin halfwave dipole antennas have certain limitations. For example, even a small scratch on the paint could break a narrow conductor trace and cause a complete loss of antenna functionality [19]. This is a significant limitation for thin dipole antennas used in harsh environments. Antenna structures for RFID applications which demand robust structures should therefore preferably have reasonable conductor width. As it also follows from Table 1, simulated values for radiation efficiency are relatively close to the measured ones, confirming the adequacy of the antenna models used in present research. 403 Radiation Efficiency, % 100 80 60 40 20 Simulated Measured 0 0 20 40 60 80 Relative amount of ink used, % a 100 Radiation Efficiency, % 100 80 Fig. 7 Height graph measured at intersect indicated in Fig. 6 60 40 20 Simulated Measured 0 0 20 40 60 80 Relative amount of ink used, % 100 b Relative RFID read range, % 100 80 60 Fig. 8 Topographic view of 3 mm section of 2 mm-wide dipole antenna having average measured sheet resistance of 238 mV/ square 40 20 0 0 Simulated Measured 20 40 60 80 Relative amount of ink used, % 100 c Fig. 5 Radiation efficiency aganist relative amount of ink used For a dipole and b bow-tie antenna, and c corresponding read range for the RFID antenna Fig. 6 Topographic view of V 3 mm section of 2 mm-wide dipole antenna having average measured sheet resistance of 2395 mV/ square 404 Just like with a filter, an antenna’s Q-value also decreases when introducing losses to the system. The VSWR ¼ 1.5 antenna bandwidth approximately doubles as it goes, from about 100 MHz for the best dipole and bow-tie conductors, to over 200 MHz for the antennas with sheet resistance of a couple of ohms. Apart from the fact that maximum antenna gain is reduced proportional to radiation efficiency, the antennas’ radiation patterns remain the same for the highloss antennas as for the low-loss ones, with simulated maximum directivity for the dipole and bow-tie antennas of, respectively, 2.50 and 2.25 dB. Fig. 9 Height graph measured at intersect indicated in Fig. 8 IET Microw. Antennas Propag., Vol. 1, No. 2, April 2007 3 Printed dipole and bow-tie antennas with variable ink layer thickness It is well known, that current density can vary significantly through the antenna structure. For example, for half-lambda antennas current density is highest in the vicinity of the feed points and slowly decreases towards the structure periphery. Figs. 1 and 3 illustrate this for the dipole and the bow-tie structures correspondingly. It is also known that power, P, loss is directly proportional to the current squared, P ¼ I 2 . R, which for a constant resistance R implies higher losses at areas of high current density. It was therefore suggested to increase the conductor layer thickness only in most ‘vital’ parts of the antenna structure, aiming for a result with increasing radiation efficiency but without significant increase in manufacturing costs due to total amount of ink used. In the discussed structures, only the innermost one third of the overall structure length was printed with thicker ink layers. Three different scenarios are investigated with different mixes of thin and thick traces. Values are all presented in the last three columns of Table 1 where the relative amount of ink used is again normalised to the thickest layers used in the preceding Section. Analysing the data present in Table 1, we can conclude that, for the dipole antenna, there is no significant benefit in using variable-layer-thickness printing. Thus, antennas printed with the same amount of ink distributed uniformly in one case, and with thicker layer at the feed points and thin at the periphery in the other, have similar radiation efficiency. It should be also noted that, even though results of computer simulations agrees well with the measurements, simulated efficiencies tend to be slightly higher than measured. These higher theoretical values might partly be due to lining and halo effects in the traces that are not considered in the simulations. With the wider bow-tie structure there is a possible gain in redistributing ink throughout the structure. A value of 21% of the relative amount of ink (Table 1, 4th column) for example gives 87% radiation efficiency, which can be compared to that of a uniformly printed bow-tie antenna with 18% used ink (Table 1, 1st column) which measured only 54% radiation efficiency. The more desirable and higher radiation efficiencies, achieved when using uniformly 44% (Table 1, 2nd column) or unevenly distributed 47% (Table 1, 6th column) relative amount of ink however, again gives more similar radiation efficiencies, 81 to 89%. 4 Printed RFID antenna One of the major targets of present research was to assess how the printed antennas would perform in an established RFID system. One of the possible ways is to compare the maximum reading distances for the commercial tags having copper-trace antennas with that of printed-antennabased tags having the same antenna pattern and the same RFID chip. We have used a commercial RFID system by iPico Holdings. A sketch of corresponding antenna structure is shown in Fig. 10. As with the previously discussed printed dipole and bow-tie antennas, structures with both uniformly distributed ink and with a thicker layer at the inner one third of the structure length were tested. Input impedance of a passive RFID tag antenna is usually far from the common 50 V, as it is intended to be loaded by the RFID chip having input impedance far from those in common RF systems [20]. For this reason, it is not possible to measure S21 directly in the same set-up as described IET Microw. Antennas Propag., Vol. 1, No. 2, April 2007 Fig. 10 Commercial RFID tag antenna pattern by iPico Holdings Our test antennas were printed in the direction of the antenna length with a thicker layer of ink at the central third of the structure (shown in bold) earlier for the transmission between two resonant antennas. Investigated RFID antennas are instead characterised by measuring maximum RFID read range with the RFID chip attached to the corresponding antenna. In passive RFID systems, read range is a critical factor. The only power is supplied to the tag by the transmitted interrogating radio wave and maximum allowed power of a transmitter is strictly regulated for each frequency band. It is well known that the power available at a certain distance from a transmitting unit is inversely proportional to the square of the distance. It follows from the Friis transmission formula [7] Pr ¼ ðPt Gt Þ Gr l2 ð4pRÞ2 ð1Þ where R is the distance between the tag and the interrogator, Pt . Gt is the effective isotropic radiated power (EIRP) of the interrogator unit, Gr is the gain of the tag (receive) antenna and l is the wavelength. As it follows from (1), when the distance between the interrogator unit and the tag is doubled, power received by the tag falls four times. It also follows from the equation that, to get the same power with two antennas with different total radiation efficiency, we need to move the less efficient antenna closer to the interrogator by a factor of the square root of the ratio of total radiation efficiency. If for example a printed antenna has a total radiation efficiency of 64% as compared to the reference one made of copper (100% radiation efficiency), the operating RFID range for a tag using the printed pffiffiffiffiffiffiffiffiffi antenna would be about 0:64 100% ¼ 80% of that of the copper one. In this way, measured sheet resistances of printed antennas can be used to characterise antenna radiation efficiency in computer simulations that, in turn, can be converted to theoretical RFID read range, due to the square root relation. Table 2 presents a comparison of the simulated and measured maximum reading distance values, together with the simulated antenna radiation efficiency and the relative amount of ink used for the ‘iPico antennas’ printed with different conductor layer thickness. A visual view of this is presented in Fig. 5c. As it is the case for the dipole and bow-tie antennas (see Section 2), simulations agree relatively well with measured values and, for half of the cases, the measured RFID read range actually exceeds the simulated ones. One unexpected exception, however, appeared for the antenna with average sheet resistance of 1130 mV/square, where measured RFID read range was significantly lower than expected. This is derived to the problem that printing the antennas with variable conductor thickness becomes problematic with very thin layers at the structure periphery, where lining and halo effects become significant. The severity of this is illustrated through the topography map in Figs. 11 and 12 405 Table 2: Maximum reading range for a commercial RFID tag with antenna printed with different ink layer thickness Sheet resistance Simulated radiation Total structure: Total structure: Total structure: Inner one third: Inner one third: Inner one third: 1130 mV/sq 245 mV/sq 50 mV/sq 84 mV/sq 88 mV/sq 43 mV/sq Outer two thirds: Outer two thirds: Outer two thirds: 2900 mV/sq 261 mV/sq 199 mV/sq 17% 42% 72% 11% 45% 53% 41% 65% 85% 33% 67% 73% 6% 56% 97% 28% 72% 75% 16% 29% 100% 21% 28% 31% 0.7 mm3 1.3 mm3 4.3 mm3 0.9 mm3 1.2 mm3 1.3 mm3 efficiency Simulated RFID read range Measured RFID read range Relative amount of ink used Total amount of ink used (Cured Vol.) Also, from Table 2, it is concluded that there is again no obvious benefit gained from redistributing the ink throughout the structure as compared to uniformly distributing the same amount of ink. The radiation pattern for the investigated RFID tag antenna is very similar to the doughnut shape of the ordinary half-wavelength dipole commonly found in the literature [7], with a simulated maximum directivity of 2.17 dB. No change in radiation pattern properties was observed for antennas with thinner ink traces. 5 Fig. 11 Results from optical laser profilometer showing 3.0 mm of a 1.0 mm wide ink trace for the printed conductor section indicated in Fig. 4, showing a pronounced lining effect Fig. 12 Height graph at the intersection indicated in Fig. 11 showing the surface roughness for about lt ¼ 3.0 mm of the wt ¼ 1.0 mm width periphery trace section of the antenna depicted in Fig. 10. The depletion of the conductive layer in the ‘valleys’ going in the direction of printing is so significant that complete breaks in the conductor layer occurred in some produced samples that were discarded. 406 Conclusions A new approach of distributing ink over a printed antenna structure has been studied. Applied ink thickness is determined in accordance to the distribution of the antennas’ current density. The main application is for mass-produced RFID-antennas, where saving fractions of a gram of ink per antenna can save thousands of dollars per day in a production line. Investigation, however, shows that it is mainly the total amount of ink used that determines the printed antennas’ radiation efficiency and not how it is distributed throughout the structures. We have found that ink layers having sheet resistances of less than 50 mV/square gives close to 100% radiation efficiency, while, if we can settle with about 80% radiation efficiency, the ink layer thickness could be halved. It was also found that with the flexographic printing technique and ink used, lines of width 1 mm or less are not preferable as they can become relatively rough. For very low ink layer thickness, flexographic lining and halo effects can also appear as severe problems, creating anisotropy in conductivity and can also lead to nonconductive traces for narrow traces printed perpendicular to the direction of the print. A good observation is that computer simulations of antennas printed with limited conductivity show radiation efficiency that agrees well with measured antenna samples. The same holds for printed RFID tag antennas, where, unless for very low radiation efficiencies, calculated relative maximum read range also agrees well with measured values. IET Microw. Antennas Propag., Vol. 1, No. 2, April 2007 6 Acknowledgments Financial support from the forest industrial research program FSCN at the Mid-Sweden University, the Knowledge Foundation and our industrial partners are gratefully acknowledged. Support in high-frequency conductivity measurement of printed ink traces by Jerzy Krupka at Warsaw Technical University, is also gratefully acknowledged. We also acknowledge support with the laser optical profilometer by Christina Westerlind at SCA Research. 7 References 1 Molesa, S.E., Volkman, S.K., Redinger, D.R., Vornbrock, Ad.F., and Subramanian, V.: ‘A high-performance all-inkjetted organic transistor technology’. Electron Devices Meeting, 2004, IEDM Tech. Digest. IEEE Int., pp. 1072–1074 2 Berggren, M., Kugler, T., Remonen, T., Nilsson, D., Miaoxiang, C., and Norberg, P.: ‘Paper electronics and electronic paper’. IEEE Conf. on Polymers Adhesives Microelectron. 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