RFID antenna modules and methods

1. An antenna module (AM) for a smart card (SC) comprising:

a substrate (MT);

a chip (CM) disposed on a surface of the substrate (MT) and flip-chip connected to pads on the surface of the substrate (MT); and

an antenna (MA) disposed on the surface of the substrate (MT), and connected with the chip (CM);

characterized by:

a support structure (DS, WC) secured to the surface of the substrate (MT), serving as a winding core for the antenna (MA);

wherein the support structure (DS, WC) comprises a tubular body portion (B) having two opposite open ends, one of which is secured to the surface of the substrate (MT), the other of which is a free end; and

wherein the support structure serves as a dam for glob-top (GT) covering at least the chip (CM) within the support structure.

2. The antenna module (AM) of claim 1 , wherein:

the support structure (WC) has a flange (F) disposed around the free end of the body portion (B).

3. The antenna module (AM) of claim 1 , further comprising:

a mold mass (MM) covering the chip (CM), the support structure (DS, WC) and the antenna (MA).

4. The antenna module (AM) of claim 1 , further comprising:

contact pads (CP) on an opposite surface of the substrate (MT) for a contact interface.

5. A smart card (SC) comprising the antenna module (AM) of claim 1 , and further comprising:

a card body (CB);

a booster antenna (BA) having an outer portion disposed around a periphery of the card body (CB); and

a coupler coil (CC) disposed at an interior area of the card body (CB);

wherein the antenna module (AM) is disposed at the interior area of the card body (CB) for inductive coupling of the antenna (MA) with the coupler coil (CC).

6. The smart card (SC) of claim 5 , wherein:

a recess (R) is provided in the card body (CB) for receiving the antenna module (AM).

7. A method of making an antenna module (AM) comprising:

flip chip mounting and bonding a chip (CM) to a substrate (MT);

characterized by:

affixing a tubular support structure (DS, WC) having two opposite open ends on a surface of the substrate (MT); and

after affixing the tubular support structure on the surface of the module tape (MT), winding a wire for an antenna (MA) around the tubular support structure (DS, WC).

8. The method of claim 7 , further comprising:

prior to mounting and bonding the chip to the substrate, applying a conductive material to at least one of bumps on the chip and pads on the substrate.

9. The method of claim 8 , wherein:

the conductive material comprises silver nanowires.

10. The method of claim 7 , further comprising:

winding the antenna (MA) using a flyer winding technique.

11. An antenna module (AM) suitable for being disposed in a card body (CB) of a smart card (SC) comprising:

a module substrate (MT); and

a chip (CM) disposed on a surface of the module substrate (MT);

characterized by:

an antenna (MA) disposed on an antenna substrate (AS) which is separate from the module substrate (MT);

an opening (OP) in the antenna substrate (AS) for accommodating the chip (CM) when the antenna substrate (AS) is joined to the module substrate (MT).

12. The antenna module (AM) of claim 11 , wherein:

the chip (CM) is and flip-chip mounted and connected to module substrate (MT).

13. The antenna module (AM) of claim 11 , wherein:

the antenna (MA) comprises wire embedded in the antenna substrate (AS).

14. The antenna module (AM) of claim 11 , wherein:

the antenna (MA) is etched from a metal layer on the antenna substrate (AS).

15. The antenna module (AM) of claim 11 , wherein:

etching is performed using a laser.