ISOLATION FILM, METHOD OF MANUFACTURING ISOLATION FILM, AND UHF RFID TAG USING ISOLATION FILM
20230312866 · 2023-10-05
Inventors
Cpc classification
H01Q17/00
ELECTRICITY
C08L101/00
CHEMISTRY; METALLURGY
H01Q1/52
ELECTRICITY
C08K3/18
CHEMISTRY; METALLURGY
G06K7/10009
PHYSICS
International classification
C08K3/18
CHEMISTRY; METALLURGY
C08L101/00
CHEMISTRY; METALLURGY
Abstract
The present disclosure provides an isolation sheet comprising a resin layer and a plurality of dispersed insulated soft magnetic particles in the resin layer. By adjusting the weight percentage of the insulated soft magnetic particles in the isolation sheet, the product of the imaginary part of the dielectric constant, the dielectric quality factor, the real part of the permeability and the magnetic quality factor of the isolation sheet falls between 3000 and 4500. The present disclosure also provides a method for producing the aforementioned isolation sheet to produce a flexible rolled isolation material for printing and bonding with the antenna of the UHF RFID tag with conveniences, thus it is highly practical. The present disclosure also provides a UHF RFID tag comprising the aforementioned isolation sheet.
Claims
1. An isolation sheet, comprising: a resin layer, and a plurality of insulated soft magnetic particles, dispersed in the resin layer; the isolation sheet having: a real part of dielectric constant, an imaginary part of dielectric constant, a dielectric quality factor, a real part of permeability, an imaginary part of permeability, and a magnetic quality factor, the dielectric quality factor being a quotient obtained by dividing the real part of the dielectric constant with the imaginary part of the dielectric constant, and the magnetic quality factor being a quotient obtained by dividing the real part of the magnetic permeability with the imaginary part of the magnetic permeability; wherein product of the imaginary part of the dielectric constant, the dielectric quality factor, the real part of the permeability and the magnetic quality factor being between 3522.40 and 4460.50.
2. The isolation sheet according to claim 1, wherein the real part of the dielectric constant is between 10 and 20, the imaginary part of the dielectric constant is between 0.8 and 1.5, the real part of the permeability is between 5.0 and 6.5, the imaginary part of the permeability is between 1.0 and 2.5, the dielectric quality factor is between 10 and 20 and/or the magnetic quality factor is between 2.0 and 5.0.
3. The isolation sheet according to claim 2, wherein the real part of the dielectric constant is between 11.15 and 16.53, the imaginary part of the dielectric constant is between 0.8 and 1.33, the real part of the permeability is between 5.23 and 6.12, the imaginary part of the permeability is between 1.23 and 2.42, the dielectric quality factor is between 12.43 and 19.50 and/or the magnetic quality factor is between 2.16 and 4.69, the product of the real part of the dielectric constant and the dielectric quality factor is between 155.40 and 311.81 and/or the product of the real part of the permeability and the magnetic quality factor is between 11.30 and 28.70.
4. The isolation sheet according to claim 1, wherein the insulated soft magnetic particles is spherical in shape, the insulated soft magnetic particles have a core part and a shell part surrounding the core part; the core part is a soft magnetic core part made of carbonyl iron powder; and the shell part is made of an insulating material and sequentially coated with a phosphate film and a silicate film by overlay coating on the core part from inside out.
5. The isolation sheet according to claim 1, wherein the plurality of insulated soft magnetic particles account for 70 wt % to 87 wt % of the isolation sheet, the resin layer is composed of a resin material, the resin material accounts for 13 wt % to 30 wt % of the isolation sheet, the resin material and the plurality of insulated soft magnetic particles account for 100 wt % of the isolation sheet in total, and particle size of the insulated soft magnetic particles is between 1 μm and 5 μm.
6. The isolation sheet according to claim 5, wherein the plurality of insulated soft magnetic particles account for 70 wt % to 77.5 wt % of the isolation sheet, and the resin material accounts for 22.5 wt % to 30 wt % of the isolation sheet.
7. The isolation sheet according to claim 5, wherein the isolation sheet has an integrated molding single-layer structure.
8. An ultra high frequency radio frequency identification (UHF RFID) tag, comprising: an antenna, and an isolation sheet according to claim 1 disposed below the antenna.
9. The UHF RFID tag according to claim 8, wherein thickness of the isolation sheet is less than 0.5 mm.
10. The UHF RFID tag according to claim 8, wherein the UHF RFID tag and/or the isolation sheet are suitable for a working frequency bandwidth of 860 MHz to 960 MHz.
11. A method for manufacturing an isolation sheet, comprising: mixing a thermoplastic elastomer with a plurality of insulated soft magnetic particles after weighing, then milling into a flexible rolled body, and subsequently cutting the flexible rolled body into a sheet-shaped isolation sheet.
12. The method for manufacturing the isolation sheet according to claim 11, wherein the plurality of insulated soft magnetic particles account for 70 wt % to 87 wt % of the isolation sheet, the thermoplastic elastomer accounts for 13 wt % to 30 wt % of the isolation sheet, the thermoplastic elastomer and the plurality of insulated soft magnetic particles account for 100 wt % of the isolation sheet in total, and particle size of the insulated soft magnetic particles is between 1 μm and 5 μm.
13. The method for manufacturing the isolation sheet according to claim 12, wherein thickness of the isolation sheet is less than 0.5 mm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026]
[0027]
[0028]
DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0029] In order to understand the technical features, contents, advantages and effects that can be achieved by the present disclosure, the expression of the present disclosure in conjunction with the attached drawings will be described in detail below. The purpose of the drawings used is only for illustrating and assisting the specification and may not necessarily represent the actual proportion and precise configuration after the implementation of the present disclosure. Therefore, the interpretation of the proportion and configuration relationship of the attached drawings should not limit the scope of the present disclosure in actual implementation, which is hereby stated.
[0030] In order to make the description of the content disclosed by the present disclosure more detailed and complete, the following description provides explanatory descriptions for the embodiment and specific examples of the present disclosure. However, these are not the only forms of implementation or application of the specific embodiments of the present disclosure. In addition, the use of “˜” and “between . . . and . . . ” in this specification and the claims refers to a numerical range that includes the values before and after the “˜” and “. . . and . . . ” as the lower limit and upper limit values. The term “wt %” in this specification and the claims refers to weight percent and the term “particle size” refers to the particle size measured using a laser particle size analyzer.
[0031] <Structure of the Isolation Sheet and UHF RFID Tag>
[0032] Referring to
[0033] The resin layer 321 is composed of a resin material that can be a thermoplastic polyurethane elastomer or a thermoplastic polyolefin elastomer. The resin material accounts for 13 wt % to 30 wt % of the isolation sheet.
[0034] The insulated soft magnetic particles 322 are spherical in shape. Each insulated soft magnetic particle 322 has a core part 3221 and a shell part 3222 surrounding the core part 3221. The core part 3221 is made of a soft magnetic material. The core part 3221 is a carbonyl iron powder ball. The shell part 3222 is made of an insulating material and sequentially coats the core part 3221 with a phosphate film and a silicate film by overlay coating from the inside out. The phosphate film accounts for 0.5 wt % to 5 wt % of the core part 3221 and the silicate film accounts for 0.5 wt % to 3 wt % of the core part 3221. The particle size of the insulated soft magnetic particles 322 is between 1 μm and 5 μm. The plurality of insulated soft magnetic particles 322 account for 70 wt % to 87 wt % of the isolation sheet. Preferably, the resin material and the plurality of insulated soft magnetic particles account for 100 wt % of the isolation sheet in total.
[0035] <Manufacturing Method of the Isolation Sheet>
[0036] After a thermoplastic polyurethane elastomer and insulated soft magnetic particles are weighed and mixed according to the weight percentages listed in the following Table 1 (comprising Table 1-1 and Table 1-2), put into a mixing mill for mixing. After fully mixing the thermoplastic polyurethane elastomer and the insulated soft magnetic particles to form a uniform gel material, the material is discharged. Next, the gel material is passed through a rolling mill and is milled according to the thicknesses listed in Tables 1 and 2 to form a flexible rolled body and then cut into sheets to prepare the isolation sheets of Embodiments 1-3 and Comparative Examples 1-2. Therefore, the isolation sheet is an integrated molding single-layer structure. Integrated molding means that the isolation sheet is formed by the same process (rolling mill) without assembly. Among them, Comparative Examples 1-2 use insulated soft magnetic particles with sheet-shaped FeSiCr (D) and with sheet-shaped FeSiAl (E) instead of spherical carbonyl iron powder for the core parts.
[0037] <Evaluation and Testing for the Performance of the Isolation Sheet>
[0038] Referring to
TABLE-US-00001 TABLE 1-1 Proportion Material for the Proportion of the insulated for core part soft the resin of the magnetic material insulated particles in the in the soft isolation isolation magnetic sheet sheet ε′ × Qε × Item particles wt % wt % ε′ ε″ μ′ μ″ Qε Qμ ε′ × Qε μ′ × Qμ μ′ × Qμ Embodi- spherical 77.5 22.5 11.15 0.8 6.12 1.23 13.94 4.69 155.40 28.70 4460.50 ment carbonyl 1 iron powder (A) Embodi- spherical 77.5 22.5 16.53 1.33 6.1 1.99 12.43 3.06 205.44 18.67 3834.82 ment carbonyl 2 iron powder (B) Embodi- spherical 70 30 15.99 0.82 5.23 2.42 19.50 2.16 311.81 11.30 3522.40 ment carbonyl 3 iron powder (C) Com- Sheet- 77.5 22.5 29.34 13.31 13.2 3.98 2.20 3.31 64.68 43.69 2825.82 parative shaped example FeSiCr 1 (D) Com- Sheet- 70 30 17.87 5.3 11.85 6.18 3.37 1.92 60.25 22.75 1370.86 parative shaped example FeSiAl 2 (E)
TABLE-US-00002 TABLE 1-2 Thickness of the Maximum Recovery isolation sheet reading percentage Item (mm) distance (m) % Embodiment 1 0.5 2.00 53.1 1.0 3.76 100 Embodiment 2 0.5 1.93 51.3 1.0 2.63 69.9 Embodiment 3 0.5 1.51 40.2 1.0 2.40 63.8 Comparative 0.5 0.50 12.5 example 1 1.0 0.90 22.5 Comparative 0.5 0.50 12.5 example 2 1.0 0.60 15.0
[0039] In table 1 (comprising Table 1-1 and Table 1-2), ϵ′ represents the real part of the dielectric constant, ϵ″ represents the imaginary part of the dielectric constant, Qϵ represents the dielectric quality factor, μ′ represents the real part of the permeability μ″ represents the imaginary part of the permeability and Qμ represents the magnetic quality factor. The dielectric quality factor (Qϵ) is the quotient obtained by dividing the real part of the dielectric constant (ϵ′) with the imaginary part of the dielectric constant (ϵ″). The magnetic quality factor (Qμ) is the quotient obtained by dividing the real part of the permeability (μ′) with the imaginary part of the permeability (μ″). ϵ′×Qϵ represents the product of the real part of the dielectric constant (ϵ′) and the dielectric quality factor (Qϵ) and μ′×Qμ represents the product of the real part of the permeability (μ′) and the magnetic quality factor (Qμ).
[0040] It may be known from Table 1 (comprising Table 1-1 and Table 1-2) that when the thickness of the isolation sheet is 0.5 mm as shown as Examples 1 to 3, the recovery percentage is greater than 40% and the maximum reading distance is greater than 1.50m, so they are qualified products. On the other hand, in Comparative Examples 1 and 2, when the thickness of the isolation sheet is 0.5 mm, the recovery percentage is less than 40% and the maximum reading distance is less than 1.50 m, so they are unqualified products. Table 1 (comprising Table 1-1 and Table 1-2) further shows that the “electromagnetic factor” of Examples 3, 2, and 1 are 3522.40, 3834.82, and 4460.50, respectively. The electromagnetic factor is the product of the imaginary part of the dielectric constant (ϵ′), the dielectric quality factor (Qϵ), the real part of the magnetic permeability (μ′) and the magnetic quality factor (Qμ). Therefore, the electromagnetic factor of the isolation sheet of the present disclosure ranges from 3000 to 4500, preferably from 3522.40 to 4460.50 and more preferably from 3550 to 4000. As shown in Table 1 (comprising Table 1-1 and Table 1-2), the higher the value of the electromagnetic factor, the higher the recovery percentage. For example, the electromagnetic factors of Examples 3, 2 and 1 are 3522.403834.82
4460.50 respectively that gradually increases, the recovery percentages of Examples 3, 2, and 1 are 40.2%, 51.3%, and 53.1% respectively, also gradually increases. Therefore, the “electromagnetic factor” mentioned in the present disclosure is highly positively correlated with the recovery percentage. In other words, the isolation sheets may be designed with specific thickness and recovery percentages based on the electromagnetic factor, which is a major creative aspect of the present disclosure. The “electromagnetic factor” indicates that the isolation sheet of the present disclosure takes into account the combined effects of electrical and magnetic properties in the integrated molding single-layer structure, rather than separately considering the electrical or magnetic effects in each layer before stacking and assembling in the multi-layer structure.
[0041] Moreover, ϵ′ may be between 10 and 20, ϵ″ may be between 0.8 and 1.5, μ′ may be between 5.0 and 6.5, μ″ may be between 1.0 and 2.5, Qϵ may be between 10 and 20 and/or Qμ may be between 2.0 and 5.0. As shown in Table 1 (comprising Table 1-1 and Table 1-2), preferably, ϵ′ may be between 11.15 and 16.53, ϵ″ may be between 0.8 and 1.33, μ′ may be between 5.23 and 6.12, μ″ may be between 1.23 and 2.42, Qϵ may be between 12.43 and 19.50, Qμ may be between 2.16 and 4.69 and the product of ϵ′ and Qϵ may be between 155.40 and 311.81 and/or the product of μ′ and Qμ may be between 11.30 and 28.70.
[0042] Additionally, it is preferable that the plurality of insulated soft magnetic particles account for 70 wt %˜77.5 wt % of the isolation sheet and the resin material accounts for 22.5 wt %˜30 wt % of the insulating sheet. The resin material and the plurality of insulated soft magnetic particles account for 100 wt % of the isolation sheet in total.
[0043] <Unexpected Effect 1>
[0044] Table 2 shows the production of isolation sheets of different thicknesses using the thermoplastic polyurethane elastomer and insulated soft magnetic particles of Example 1 in Table 1 (comprising Table 1-1 and Table 1-2) and the maximum reading distance and recovery percentage are measured according to the aforementioned method and equipment.
TABLE-US-00003 TABLE 2 Thickness of the Maximum Recovery isolation sheet reading percentage Item mm distance m % Embodiment 1 0.1 mm 0.33 8.7 0.2 mm 0.66 17.6 0.3 mm 1.24 32.9 0.4 mm 1.60 42.4 0.5 mm 2.00 53.1 0.8 mm 3.13 83.0 1.0 mm 3.76 100.0 2.0 mm 5.82 154.7 3.0 mm 7.33 194.7
[0045] When the thickness of the isolation sheet is 1.0 mm, the recovery percentage may reach 100% and the maximum reading distance has been restored to 3.76 m (i.e., the “original reading distance” of the UHF RFID tag). However, the unexpected discovery from table 2 is that when the thickness of the isolation sheet reaches 2.0 mm and 3.0 mm, the maximum reading distance exceeds 3.76 m and reaches 5.82 m and 7.33 m, respectively. When converted to recovery percentage, they are 154.7% and 194.7%, respectively. In other words, the surprising finding is that when the thickness of the isolation sheet of the present disclosure exceeds a specific thickness, it will cause a gain effect on the isolation sheet, which will make the maximum reading distance exceed or equal the original reading distance. This breaks the limitation mentioned in the prior art or literature, which previously believed that the maximum reading distance cannot be greater than the original reading distance.
[0046] Table 2 further shows that when the thickness of the isolation sheet is 0.4 mm, the recovery percentage is 42.4%, which is greater than the passing standard of 40%, and the maximum reading distance is 1.60 m, which is also greater than the passing standard of 1.50 m. In other words, the surprising finding is that the isolation sheet of the present disclosure breaks the limitations mentioned in the prior arts 1 and 2. The prior arts 1 and 2 both believe that the isolation sheet must be greater than 0.5 mm to allow the UHF RFID reader to read the data of the UHF RFID tag.
[0047] Furthermore, table 2 shows that even when the thickness of the isolation sheet is 0.1 mm, the data of the UHF RFID tag can still be read within a distance of 0.33 m, even if its recovery percentage is only 8.7%. In other words, the surprising finding is that the isolation sheet of the present disclosure breaks the limitations mentioned in the prior arts 1 and 2. The prior arts 1 and 2 both believe that when the thickness of the isolation sheet is less than 0.5 mm, the UHF RFID reader cannot read the data of the UHF RFID tag.
[0048] <Unexpected Effect 2>
[0049] Based on the obtained commercially available isolation sheet (composition unknown) with a thickness of 5 mm, the isolation sheet with a thickness of 5 mm in Example 1 was further used on intention, the instrument and method described in the <Evaluation and testing for the performance of the isolation sheet>section are used for testing the isolation sheets but the operating bandwidth is changed to 850 MHz˜950 MHz. The test results are combined and plotted in
[0050] According to
[0051] In addition, it is further known from
[0052] <Proportion of Resin Material and Insulated Soft Magnetic Particles in the Isolation Sheet>
[0053] The present disclosure further produces isolation sheets of different proportions of resin material and insulated soft magnetic particles and different thicknesses according to Table 3 below and measures the maximum reading distance and recovery percentage using the aforementioned method and equipment.
TABLE-US-00004 TABLE 3 Proportion for the insulated Proportion soft for the magnetic resin particles material Thickness in the in the of the Maximum isolation isolation isolation reading Recovery sheet sheet sheet distance percentage Item (wt %) (wt %) (mm) (m) (%) Embodiment 70 30 0.5 0.580 15.41 1-1 1.0 1.050 27.90 Embodiment 77.5 22.5 0.5 1.998 53.08 1 1.0 3.764 100.00 Embodiment 80 20 0.5 1.862 49.47 1-2 1.0 2.344 62.27 Embodiment 87 13 0.5 0.653 17.35 1-3 1.0 0.814 21.63 Comparative 90 10 0.5 0.471 12.51 example 3 1.0 0.673 17.88
[0054] As previously described, when the thickness of the isolation sheet is 0.5 mm, a recovery percentage greater than 15% or a maximum reading distance greater than 0.5 m is acceptable. Therefore, in Embodiments 1-1, 1, 1-2 and 1-3, the recovery percentages measured with a thickness of 0.5 mm are all greater than 15% and the maximum reading distances are all greater than 0.5 m. Thus, the resin material accounts for 13 wt % to 30 wt % of the isolation sheet and the plurality of insulated soft magnetic particles 322 account for 70 wt % to 87 wt % of the isolation sheet. The resin material and the plurality of insulated soft magnetic particles account for 100 wt % of the isolation sheet in total.
[0055] In summary, the present disclosure has the following advantages: (1) The electromagnetic factors of the isolation sheet in the present disclosure are limited to the product of the imaginary part of the dielectric constant (ϵ′), the dielectric quality factor (Qϵ), the real part of the permeability (μ′) and the magnetic quality factor (Qμ) between 3000 and 4500, preferably between 3522.40 and 4460.50 and more preferably between 3550 and 4000, to achieve the effect of simultaneously matching the electrical and magnetic properties in the single-layer structure. (2) Placing the isolation sheet of the present disclosure correspondingly between the antenna of the UHF RFID tag and the metal product, excellent recovery rates may be measured. (3) When the thickness of the isolation sheet of the present disclosure exceeds a specific thickness, a gain effect is generated, which allows the maximum reading distance to exceed or be greater than the original reading distance. The limitations mentioned in prior art or literature is broken through. (4) The isolation sheet of the present disclosure has broken through the limitation that the isolation sheet must be larger than 0.5 mm in the prior arts. (5) By using the isolation sheet of the present disclosure for the UHF RFID tags, when the UHF RFID tag reader reads the antenna data, the effect of high stability and the antenna data may be read throughout the full frequency domain is achieved.
[0056] The above-described embodiments are only intended to illustrate the technical ideas and features of the present disclosure and their purpose is to enable those skilled in the art to understand the contents of the present disclosure and implement them. They cannot limit the scope of the present disclosure and any equal changes or modifications made based on the spirit of the present disclosure should still be within the scope of the present disclosure.