HK1068582A - Method and apparatus for associating on demand certain selected media and value-adding elements - Google Patents

Description

Method and apparatus for on-demand combination of selected media and value-adding elements

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Technical Field

In general, the present invention relates to a method and apparatus by which individual labels, tickets, tags, cards and the like (hereinafter collectively and individually referred to as "media", or individually referred to as "media samples") having selection features can be customized in a selective and on-demand manner by attaching one or more value-adding elements, also having selection features, to the media. More particularly, the present invention is directed to methods and apparatus for selectively integrating value-adding elements, such as radio frequency identification (hereinafter RFID) transponders, with single-type media samples in a programmed and desired manner.

Background

Other types of value-adding elements that can be incorporated into media samples include, for example, shipping tickets; parts cataloged, stored or shipped, promotional items such as coupons, tokens, currency, or other items of value to the recipient; an integrated circuit in the tag having a wire connectable to the printed antenna; the printed medium has attached or embedded attached articles with information related to the article name or use.

Thermal transfer printers are commonly used to print single type media samples. Referring to FIG. 1, a side view of a standard heat transfer printing mechanism 10 is shown. A label carrier tape 12 (also commonly referred to as a release liner) carries die-cut labels 14, adhesive-backed (hereinafter referred to simply as backsize), and typically unprinted, through the mechanism. Typically, the upper surface of each label is printed in a dot pattern formed by the fusing of the ribbon 16 onto the label as the heat transfer ribbon and label pass under a computer controlled print head.

The elastomeric covered platen roller 20 is typically driven by a stepper motor to provide a motive force to the ribbon and label by acting in a friction-driven manner on the label web 12, while the platen roller 20 also acts as a receptor for the necessary pressure applied to the print head on the ribbon-label sandwich. This pressure helps to transfer the molten ink dots from the heat transfer ribbon beneath the print head 18 to the surface of the die cut labels 14.

The thermal transfer ribbon 16 is unwound from a printer ribbon supply 22 and guided by a guide shaft 24 past the underside of the thermal print head 18. After the ink is melted from the ribbon 16 onto the printed die cut labels 26, the used ribbon is wound onto a printer ribbon take-up spool 28.

Typically, the media outlet 30 is located immediately behind the print head. Printed die cut labels 26 are typically distributed on the label carrier tape 12. An alternative peel bar 32 may be used if the user wants the printed die cut labels 26 to be automatically peeled from the label web. As the label web 12 passes over the point of the peel bar 32, the adhesive bond is broken, thereby releasing the printed die cut labels 26 from their label web 12. The peeled printed die cut label 26 is dispensed to a media exit 30. By using an alternative label web recovery mechanism 34, the excess label web 12 is provided with tension to facilitate peeling, as well as rewinding.

As will be discussed in detail below, exemplary embodiments of the present invention relate to the bonding of RFID transponders and labels, etc. together in a selective and on-demand manner to produce a "smart" label in the context of a thermal or heat transfer printer. While "chipless" RFID transponders exist and may be utilized as an example of value-adding elements in accordance with certain features of the present invention, the most common type of transponder for smart tags is one that includes an antenna and an RFID integrated circuit. Such RFID transponders include dc powered transponders and battery-less powered transponders, and come in a variety of different form factors. The general passive embedded transponder 36 shown in fig. 2 is generally thin, flat in shape. In order to be automatically inserted into the label, the in-line transponder 36 is typically made pressure sensitive self-adhesive and is fed in a single die cut and mounted at uniform intervals on an in-line conveyor belt.

Embedded transponders have been used as a component layer of identification tags and labels to carry encoded data that is stored in a non-volatile data memory area and can be wirelessly read from a remote location. For example, a camera with a radio frequency identification transponder capable of remote writing and reading is disclosed in U.S. patent No.6,173,119.

The antenna 38 of the embedded transponder 36 is in the form of a conductive trace on a non-conductive support 40 having a flat solenoid or similar shape. An antenna wire 42 is also disposed thereon with a non-conductive layer therebetween. The RFID integrated circuit 44 of the embedded transponder 36 includes a non-volatile Memory, such as an EEPROM (Electrically Erasable Programmable read only Memory); a power generation subsystem (generated by excitation of the reader-induced radio frequency field); a radio frequency communication capacity; internal control functions. An RFID integrated circuit 44 is mounted on the non-conductive support 40 and operatively connected by antenna wires 42. These inserts are typically individually packaged, either in a "Z" shape, or in roll-like, in-line conveyor 46, as shown in fig. 2.

It is known how to insert a transponder into a medium using a pressing device to form a "smart label" and then print information on the surface of the smart label. For example, the application white paper entitled RFIDT technology & Smart Labels (9/14.1999; P/N11315L Rev.1 from Zebra technologies, Inc.). As another example, a document entitled "A White Paper on the Development Of AIM Industry Standards For 13.56MHz RFID Smartlabs And RFID printers/Encoders" (24/5/2000; Green P. Hohberger, PhD). Both of these documents are hereby incorporated by reference into the present application, as if fully set forth herein.

It is also known how to apply pressure sensitive labels to business formats using label application equipment. Several companies' such devices have appeared in the us market more than a year before the filing date of the present application.

Zebra technology corporation is the leading manufacturer of press-related products, including many on-demand heat transfer presses, which embody many of the technical characteristics disclosed in the white paper references cited in the two books above. An example of such a "smart label" printer that has appeared on the market more than one year before the filing date of the present application is the Zebra model R-140.

Such products are also satisfactory for the use intended by the manufacturer. However, further improvements are desirable. Certain features and advantages of the invention will be apparent from the description that follows.

Drawings

The objects and advantages of the present invention will become readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIG. 1 is a side schematic view of a standard heat transfer label printing mechanism;

FIG. 2 is a schematic diagram of a plurality of passive embedded RFID transponders being transported with adhesive backing on an embedded conveyor belt;

FIG. 3 is a schematic side view of a heat transfer printer embodying many of the features of the exemplary embodiments of the present invention disclosed in this application;

FIG. 4 is a front cross-sectional view of a portion of the thermal transfer printer shown in FIG. 3, illustrating the compression attachment mechanism in detail;

FIG. 5 is a front cross-sectional schematic view of the thermal transfer printer of FIG. 3 with the responder dispensing mechanism in a fully retracted initial position;

FIG. 6 is a schematic block diagram of a portion of the critical electronic subsystems and components of the thermal transfer printer shown in FIG. 3;

FIG. 7 is a process flow diagram illustrating some of the key process steps performed by the processing unit shown in FIG. 6 for each print job performed by the thermal transfer label printer shown in FIGS. 3-6;

FIG. 8 is a schematic cross-sectional front view of the thermal transfer printer of FIG. 3 with the transponder dispensing mechanism of FIG. 5 in a forward position so that the RFID transponder can be positioned in a desired location and orientation in accordance with the position of the stripped layer of die-cut labels printed by the thermal transfer printer;

FIG. 9 is a schematic cross-sectional front view of the heat transfer printer of FIG. 5 using the pinch-and-apply mechanism shown in detail in FIG. 4 to permanently apply a programmed RFID transponder to a media sample to be printed by the heat transfer printing mechanism, wherein a linear actuator is used to retract a dispensing mechanism to peel an embedded web from the back of the programmed transponder to expose an adhesive layer on the back of the programmed transponder;

FIG. 10 is a schematic cross-sectional side view of the thermal transfer printer of FIG. 3 with a die cut label/programming responder sandwich formed and reattached to the die cut label web;

FIG. 11 is a schematic side view of a heat transfer printing mechanism similar to that disclosed in FIG. 7 embodying many of the features of another exemplary embodiment of the present invention disclosed in this application and enabling an adhesive-backed value-adding device, such as an RFID transponder, to be attached to a rigid media without its adhesive layer;

FIG. 12 is a schematic side view of the thermal printer of FIG. 11 with the tack-free programmed RFID transponder in a dispensing position in accordance with the value-adding mechanism;

FIG. 13 is a schematic side view of the thermal transfer printer of FIG. 11 with a back-adhesive programmed RFID transponder attached to a rigid media;

FIG. 14 is a schematic side view of the thermal transfer printer of FIG. 11 with a hard media having an adhesively backed programmed RFID transponder attached thereto moving forward to an exit dispensing position;

FIG. 15 is a flowchart illustrating some of the key procedural steps performed by the processing unit shown in FIG. 6 for each print job performed by the thermal transfer printer shown in FIGS. 11-14;

FIGS. 16A through 16D are schematic diagrams of two types of RFID integrated circuit labels that are attached to respective types of printed antennas to make RFID transponders in an exemplary variation utilizing a thermal transfer printer as shown in FIGS. 11-15;

FIGS. 17A and 17B are schematic illustrations of the front and back sides of a sheet set media with various value-adding elements printed in an on-demand manner during fabrication in accordance with an exemplary embodiment of the present invention;

FIG. 18 illustrates 4 value-adding elements added in specific combinations to a patch medium as in FIG. 17 by the exemplary production process as shown in FIG. 19;

FIG. 19 is a top schematic view of an exemplary fabrication process incorporating forms of two exemplary embodiments of the present invention for selectively and responsively configuring the postcard media as in FIG. 17 for application of one or more value-adding elements as in FIG. 18 to the postcard media;

FIGS. 20-23 are schematic side views of a heat transfer printing mechanism embodying many of the features of the invention disclosed in the application, namely, encoding RFID transponders in a selective and on-demand manner and applying them to pre-printed die-cut labels that are adhesive-backed, under program control;

fig. 24 is a side schematic view of a heat transfer printing mechanism similar to that shown in fig. 20-23, i.e., an RFID transponder is encoded in a selective and on demand manner and applied to linerless media under program control.

Detailed Description

While this invention is susceptible of embodiment in different forms, there is shown in the drawings only some of the presently preferred embodiments which will be discussed in detail hereinafter. It is to be understood that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this application, section of this application ("detailed description of the invention") relates to a definition in the United states patent office, and should not be used to limit the subject matter disclosed herein.

Referring to FIG. 3, a schematic side view of a thermal transfer printer 48 embodying some of the features of the invention disclosed in this application is shown. In the embodiment of the present invention shown in FIG. 3, the thermal transfer printer 48 comprises a standard thermal transfer printing mechanism that includes all of the components shown in FIG. 1. The printer 48 also includes a value-adding mechanism 50 including decision-making components 54 through 70. the value-adding mechanism 50 may apply value-adding elements, such as programmed RFID (radio frequency identification) transponders 52, to the media samples after they have been printed, as will be discussed in greater detail below.

It should be appreciated that the value adding mechanism 50 may be manufactured separately from the heat transfer printing mechanism, allowing existing heat transfer printing presses to be retrofitted to operate in accordance with certain features of the invention disclosed in this application. It should also be understood that although the illustrative embodiments of the invention disclosed herein relate to thermal transfer printing, the invention is equally applicable to other printing techniques.

Returning to fig. 3, the thermal transfer printer 48 enables a back-adhesive programmed RFID transponder 52 to be selectively applied to a printed die cut media sample (e.g., printed die cut label 26) by an addition mechanism 50 under program control, as will be discussed in particular detail below. The resulting printed die cut label/programming responder composite (26/52) is fed to media outlet 30 and optionally peeled from the label carrier tape.

Immediately after printing, the printed die cut labels 26 pass over the tips of the peel bar 32 and are released from the label carrier tape 12. The peel-and-layer process by peeling the cross-bar 32 exposes the adhesive on the bottom (non-printed) side of the printed die-cut label 26.

The printed die cut label 26 then proceeds in a linear fashion through a smooth and apertured vacuum guide 54 of a pinch and apply mechanism 56. The centrifugal fan 58 draws air 60 out, creating a slight vacuum in the plenum 62. This maintains a slight upward force on the printed die-cut labels 26, keeping the labels adhered under the smooth perforated vacuum guide 54. The strength of the vacuum force is at a level that does not impede the forward movement of the printed die cut labels. The plenum 60 extends along a central axis generally perpendicular to the path of travel of the labels.

The stripped label web 12 is wrapped around a buffer ring type roller 64, the roller 64 serving to control the flow direction of the label web 12 around a responder dispensing mechanism 66 (fig. 6). The buffer ring type roller 64 is free to move up and down to retrieve and replace excess label web 12 at various times in the process.

In an embodiment, one function of the dispensing mechanism 66 is to place the adhesive-backed REID responder 52 underneath and in operative communication with the printed die cut labels 26. The REID responder 52 is conveyed by the inline carrier tape 46 as shown. The pinch applicator mechanism 56 (fig. 3) then extends the plenum 60 downward using a bellows 70 so that the rigid perforated vacuum guide 54 presses lightly against the printed side of the printed die-cut labels 26. This causes the exposed adhesive side of the printed die cut label 26 to be applied to the upper surface of the RFID transponder 52.

The label-responder complex (26/52) moves forward past the nip wheel 72, the nip wheel 72 being comprised of an upper nip roller 74 and a lower nip roller 76. The pressure of the nip wheel causes the adhesive on which the die cut labels 26 have been printed to be applied to the RFID transponders 52 and the label-transponder laminate to be reapplied to the label web 12. The resulting die cut label-responder-label web composite (26/52/12) then exits the value-adding mechanism 50. As is well known, the label web 12 may be optionally peeled from the die cut label/transponder laminate (26/52) by using an exit peel bar 78 and an optional label web recovery mechanism 34.

Typically only the lower nip roller 72 is driven and the surface speed driven is the same as that of the nip roller 20. This allows the printed die cut label 26 to be properly positioned in the printer 48 without distortion, for example, when it is longer than the distance between the nip roller 20 and the pinch roller 72.

FIG. 4 is a detailed cross-sectional view of a portion of the pinch-fit mechanism 56 shown in FIG. 3. The enclosed housing 80 and enclosed bellows 70 form an enclosed plenum 62 containing an incomplete vacuum that is applied to the printed media as it passes through the heat transfer printer 48. The air pressure of the lower surface of the printed die cut label 26 causes the label to be temporarily attached to the perforated vacuum guide 54.

The vacuum of plenum 62 is created by centrifugal fan 58 expelling air 60 from being drawn from aperture 82, through bores 84 and 86, and into fan inlet 88. A bellows 70 is connected to the base plate 90 and to the perforated vacuum guide plate 54 via drive brackets 104 to enable the perforated vacuum guide plate 54 to maintain a sealed vacuum in the plenum 62 as it moves up and down.

The base plate 90 forms part of the heat transfer printer housing, with the housing 80 being secured to the base plate 90. Pinch-fit mechanism 56 is fixed to housing bracket 92 and comprises a two-part solenoid structure, namely a stationary solenoid 94 connected to housing bracket 92 and solenoid plunger 68 connected to gas spring plunger 97 by connector 100. The backbone of gas spring 98 is free to slide within linear bearing 102 and is indirectly connected to apertured vacuum guide plate 54 by drive bracket 104 as shown. A return spring 106 between moveable coupling 100 and fixed base 90 provides a force to return solenoid plunger 68 and iron plate 96 to their original positions when the solenoid is de-energized.

One function of gas spring 98 is to impart a constant force to vacuum guide plate 54 that does not vary with the extent of the wind chamber. The gas spring 98, acting in conjunction with the return spring 106 and the driven components, also acts as a viscous damping to the movement of the perforated vacuum guide plate 54, i.e., when the solenoid 94 is energized, the gas spring 98 disengages the perforated vacuum guide plate 54 from the snap action of the solenoid plunger 68 and pulls the iron plate 96 down. Gas dampers and other viscous dampers may be used in place of gas springs 98 to perform the same function.

If compressed gas is available, alternative design concepts may be used for the compression attachment mechanism. The incomplete vacuum in the plenum 62 may be created by flowing compressed gas through a venturi. The hold down actuator may be a gas cylinder having a controlled flow of gas therein that serves the same function as the gas spring 98, i.e., extending the perforated vacuum mechanism downwardly. Alternatively, in an alternative pinch applicator mechanism 56 having a non-extended plenum 62, the pinch may be achieved by applying a gas stream that is blown through perforated vacuum guide 54 onto the labels.

Referring to FIG. 5, the thermal transfer printer 48 is shown in cross-section in FIG. 3 with the dispensing mechanism 66 in a fully retracted home position. In the embodiment of the invention shown in fig. 5, printer 48 programs the memory in RFID integrated circuit 44 with RF signals 108 that are transmitted by transponder programming antenna 110. In the fully retracted position shown in fig. 5, the programmed RFID transponder 52 is located directly below the transponder programming antenna 110.

In the illustrative embodiment of the present invention, the dispensing mechanism 66 includes responder transport rollers 112, 113, 115 and a rigid guide plate 114, as well as a linear actuator 116. The linear actuator 116 advances and retracts the rigid guide plate 114 so that the programmed RFID transponder 52 is positioned under the die cut label 26 at the desired insertion location.

To properly position the programmed transponder 52 under the printed die-cut label 26, a frictionless roller drive mechanism 118, rotated by a frictionless roller stepper motor 120, is synchronized with the linear actuator 116 to regulate the movement of the transponder embedded web 46. This movement is also synchronized with the responder supply spool 122 and the inline web take-up spool 124 with the inline web take-up spool 132. Supply roll drive 126 provides a computer controlled release resistance and a braking function to responder supply roll 128. The recovery roller drive 130, acting on the inline web recovery spool 124, maintains the inline web 46 at a suitable tension to prevent web slippage of the frictionless roller drive mechanism 118. the mechanism 118 is capable of providing a peel tension to peel the inline web 46 from the programmed RFID transponder 52 at the inline web peel bar 134.

The transponder position sensor 136 detects the transponder 52 when it is properly positioned below the transponder programming antenna 110. The transponder position sensor 136 is part of an electronic control device, as shown in fig. 6, for controlling the movement of the embedded web 46.

FIG. 6 is a schematic block diagram of the major electronic components of the thermal transfer printer 48 shown in FIG. 3. In the illustrative embodiment of the present invention, the printer 48 includes a processing unit 138 connected to a processor bus 140 by various components. The processing unit 138 executes a set of program commands from a user that are input through the printer I/O port 142 and stored in the memory 144. As shown in fig. 6, the processing unit 138 is operatively electrically coupled to the following components via a processor bus 140: a platen drive 146 to drive the platen roller 20, the thermal print head 18, a responder programmer 148 connected to the responder programming antenna 110, the responder position sensor 136, the linear actuator 116, the supply spool drive 126, the frictionless roller stepper motor 120 to operate the frictionless roller drive mechanism 118, the embedded conveyor belt take-up spool drive 130, and the hold-down solenoid 94.

Fig. 7 is a flow chart illustrating the various procedural steps performed by the processing unit 138 shown in fig. 6 to effect various print jobs through the thermal transfer printer 48. Programming languages suitable for programming print jobs in connection with the invention disclosed in this application include: such as the printer universal language zpli * manufactured by Zebra technologies, inc.

In process 150, processor 138 (FIG. 6) first retrieves from memory 144 the parameters of the on-demand or selection mode of the print job that the user wants to complete. For example, a user may store in memory 144 a set of commands that will cause printer 48 to print a batch of 100 die cut labels, where each die cut label will be a "smart label" with a programmed RFID transponder 52. It should be understood that all such "on-demand" print jobs are intended to be of some relevance to the present invention, i.e., the print jobs (in the presently discussed preferred embodiment of the present invention) include at least one smart label.

Returning to fig. 7, at program step 152, the processing unit 138 (see fig. 6) determines whether the die cut labels 14 to be printed will be applied to a programmed RFID transponder 52. If not, a printed die cut label 26 is formed at process 154. If, at process step 156, it is determined that the entire print job is complete, then the process group work is complete. If the print job is not complete, a new die cut label is properly positioned under the print head 18 for the next round of printing, while cataloging the label format, at process 158. The processing unit 138 then executes the command, returning to program step 152.

If the processing unit 138 determines at program step 152 that the die cut labels 14 to be printed will have RFID transponders 52 attached thereto, then the RFID transponders 52 are programmed at process 160 and then checked for validity and proper programming at process 162. If the programmed RFID transponder 52 is properly verified, die cut label 14 is printed at process 163 to form a printed die cut label 26, and then the programmed RFID transponder 52 is attached to the printed die cut label 26 by operating the value adding mechanism 50 at process 164. The processing unit 138 then executes a program step 156 to see if the print job has been completed as described above. If the print job is not complete, then the media and print formats are catalogued at process 158 and the processing unit 138 returns to program step 152.

Responder programming and verification typically occurs prior to media printing so that smart labels with defect responders 52 can be identified by printing "void" on the label, which is printed differently than the normal label format discussed above. The printer 48 then typically ejects the defective smart label and automatically repeats the process until a fully functional smart label is produced with the properly programmed transponder and the correct label format.

This ensures that a complete process, in which the user wants to make a batch of labels in a manner associated with a particular on-demand print job, is accurately performed. For example, if processing unit 138 determines that programmed RFID transponder 52 is not valid during verification process 162, the transponder may be directly removed. In addition, at step 163, appropriate indicia such as "void" is printed on die cut labels 26, and then the invalid RFID transponder 52 is applied to the label on which the "void" has been printed at process 164 so that the transponder 52 that is properly identified as defective can be removed from the printer 48. The processing unit 138, in and out of processes 160 and 162, programs and collates a new RFID transponder 52, prints an appropriate die cut label 26, and applies the two together in process 164, and so on until a printed correct die cut label 26 is produced with an embedded collated programmed RFID transponder 52. The process then continues at process step 156 by testing whether the print job is complete.

The example of fig. 8-10 illustrates the application of a programmed RFID transponder 52, or any other suitable value-adding element, to the printed die-cut label 26 (step 164 shown in fig. 7). The processing unit 138 (fig. 6) advances the linear actuator 116 and causes the supply spool drive 126 to unwind the responder supply spool 128 while the frictionless roller stepper motor 120 and the take-up spool drive 130 also unwind approximately the same length of the embedded web 46. This continues until a new unprogrammed RFID transponder 166 is properly within range of the transponder position sensor 136.

In fig. 9, processing unit 138 (fig. 6) activates pinch-and-apply mechanism 56. By passing current to solenoid 94, the magnetic force on iron plate 96 activates solenoid plunger 68, solenoid plunger 68 passes through coupler 104 and gas spring plunger 97, and then pressurizes gas spring 98. A nearly constant compressive force, which does not vary with the extent of the plenum, is transmitted through the backbone of the gas spring 98 to the drive bracket 104, which then drives the bracket 104 to extend the bellows 70 and thus the plenum 62. This causes the rigid perforated vacuum guide 54 to press the adhesive side of the printed die cut labels 26 onto the programming responder 52, the pressing process using the rigid guide 114 as an anvil. This applies the programmed RFID transponder 52 to the printed die cut label 26.

Once the compaction process is complete, the processing unit 138 retracts the linear actuator 116 while maintaining the supply spool drive 126 in a braking state, as described above, so that a new unprogrammed RFID transponder 166 remains secured beneath the transponder position sensor 136. The processing unit 138 activates the frictionless roller stepper motor 120 in coordination with the movement of the linear actuator 116 to enable recovery of excess inline conveyor belt 46 and maintain tension in the inline conveyor belt 46 through the action of the frictionless roller drive mechanism 118. The tension of the frictionless roller drive mechanism is maintained by energizing the take-up reel drive 130, which also causes the take-up reel 124 to wind back excess embedded carrier tape 46.

The retraction of the guide plate 114 in the linear actuator 116, along with the tension on the embedded web 46, assists in peeling the embedded web 46 from the adhesive layer beneath the programmed RFID transponder 52 at the embedded web peel bar 134, which programmed RFID transponder 52 is to be applied to the printed die cut label 26. This stripping process continues until the guide plate 114 is fully retracted to the position shown in fig. 5. The new unprogrammed RFID transponder 166 is now properly positioned below the transponder programming antenna 110 for fast programming.

Since the programmed RFID transponder 52 has been applied to the printed die cut label 26, the processing unit 138 deactivates the pinch-and-apply mechanism 56, which retracts under the force of the return spring 106.

In fig. 10, the die cut label/transponder smart label laminate (26/52) is advanced under the action of the platen roller 20, sliding across the smooth apertured vacuum guide 54 until the next unprinted die cut label 14 is positioned under the print head 18 for the next round of printing. The overlaminate (26/52) continues to be driven by the drive nip roller 76 and is reapplied to the label carrier tape 12 at the nip wheel 72. The printed programmed RFID smart label with the embedded programmed RFID transponder 52 is now ready for manufacture and the laminated smart label (26/52/12) is fed to the label outlet 30. In a similar manner as described in fig. 1, the label web 12 may also be optionally peeled from the printed smart labels (26/52).

Alternatively, the label web 12 that is peeled apart at 32 (fig. 3) may be removed from the system by using a recycling mechanism similar to 34. In this example, the second supply roll of label web 12 is available for restuck of the label laminate at the pinch wheel 72 (25/52/12), thereby eliminating the need for the buffer ring roller 64.

Fig. 11-15 illustrate an exemplary modification of the heat transfer printer 48 (shown in fig. 3) designed to print tickets, labels, plastic cards, and other rigid media without an adhesive layer. The ticket and sign printer 168 is comprised of a heat transfer printing mechanism 10, a pinch and apply mechanism 56, a dispensing mechanism 66, and a cutting mechanism 170. The embodiments shown in fig. 11-15 are equally applicable to the application of self-adhesive transponders to printed self-adhesive labels.

Note that elements illustrated in the embodiments of fig. 3-10, but not specifically shown in fig. 11-13, may also be present in an actual product that includes all or a portion of the elements and features disclosed in each of the illustrations (3-14) of the present invention shown. However, since the depicted components that are not shown do not play a role in the further exemplary embodiment of FIGS. 11-14, these components are not shown in FIGS. 11-14 for purposes of simplicity.

Referring to fig. 11, the programmed RFID transponder 52 itself constitutes a transponder label 172 by attaching a die cut transponder web 174 to the upper surface of the adhesive-backed programmed RFID transponder on the in-laid web 46. Since the rigid media 176 is often supplied in a continuous state, the media may optionally be cut into lengths after printing. Shown in fig. 11 is an alternative cutter 170, located between nip rollers 74, 76 and media outlet 30, containing a cutting blade 178. In addition, the motorized cutting mechanism 170 is coupled to the processor unit 138 (shown in FIG. 6) via the processor bus 140 (shown in FIG. 6) as part of the heat transfer ticket and signage printer.

In FIG. 12, pinch-fit mechanism 56 is extended in a similar manner as described in FIG. 9. Processing unit 138 (fig. 6) energizes solenoid 94 in pinch laminating mechanism 56, which extends bellows 70 and presses perforated vacuum guide plate 54 against transponder label 172. In a manner similar to that shown in fig. 9, the guide plate (not shown) of the dispensing mechanism 66 is retracted to allow the inline carrier 46 to be peeled away from the responder tag 172 at the inline carrier peel bar 134 (see fig. 9), thereby exposing the adhesive side beneath the responder tag 172.

In fig. 13, when solenoid 94 is de-energized, pinch-fit mechanism 56 is fully retracted by spring 106 and transponder tag 172 remains attached under perforated vacuum guide 54 by the vacuum force generated by centrifugal fan 58. At this point, the exposed adhesive side below the transponder tag 172 is positioned above the path of the hard media 176.

The hard media 176 (which may be a ticket, label, plastic card, multi-ply label or the like) is then printed and then fed forward under the action of the rollers 20 to where the transponder label 170 can be placed. Referring to fig. 14, when the printed rigid media 176 is in the correct position, the pinch-fit mechanism 56 presses the transponder label onto the printed rigid media 176. Note that during the pressing process, the guide plate of the dispensing mechanism 66 may optionally extend above the printed hard media so that the hard guide plate 114 can be used as an anvil for the press fit mechanism 56.

In fig. 14, the responder label/printed hard media overlay (172/176) now continues to move forward through the nip rollers 74 and 76, where the responder label 172 is permanently affixed to the printed hard media 176 by the pressurization of the nip rollers 74 and 76. If the transponder/media composite is made using a discontinuous hard media 176 (172/176), the composite is ejected from the media outlet.

If a continuous hard media 176 is used, the hard media carrying the transponder media laminate (172/176) may optionally be cut into segments by the cutting mechanism 170. The cutting process is performed under the control of print job software, as shown in FIG. 15, for example, by the processing unit 138 activating an electrically controlled cutting blade 178. In this case, the cut intelligent tickets or signs exit at 30 and the remaining hard media 16 is retracted by the action of the platen roller 20 to a position below the print head 18 to begin the next round of printing.

Fig. 15 is a flowchart illustrating the program steps executed by the processing unit 138 shown in fig. 6 to perform various print jobs through the thermal transfer printer 48. Note that many of the procedural steps and processes in fig. 15 are the same or similar to those in the flowchart of fig. 7. In process step 150, the processor 138 first retrieves from the memory 144 the parameters of the print job that the user wants to perform in an on-demand manner. For example, the user may store in memory 144 (as shown in FIG. 6) a set of commands that will cause ticket and ticket printer 168 to print out a batch of 21 tickets in a continuous roll of hard media 176, of which only the first sheet will be made into a "smart label" with a programmed RFID transponder tag 172. It should be understood that all "on-demand" print jobs are intended to have a degree of relevance to the present invention, i.e., the print jobs (in the preferred embodiment of the invention described) contain at least one intelligent ticket or sign.

Referring to fig. 15, in a program step 180, the processing unit 138 (see fig. 6) determines whether the rigid media sample to be printed will have a programmed RFID transponder label 172 attached thereto. If not, a printed ticket is formed in process 181. At process step 182, a determination is made as to whether the media sample is to be cut. When a non-continuous media (e.g., plastic card) is used, the finished media sample is ejected at the media outlet 30 at process 183, while a new media sample is placed under the print head 18 for the next print run.

When the printed continuous hard media needs to be cut, then in process 184 the continuous hard media 176 is placed in the cutting mechanism 170 at the cutting point between the cutting blades 178. The processing unit 138 activates the motorized cutting mechanism 170 to cut the tickets, tags, smart tickets, or smart tags to supply and deliver the hard media to the media outlet 30. The continuous hard media is then re-supplied by the impression roller 20 to the beginning of the print position below the print head 18 for the next round of printing.

If, at step 156, it is determined that the entire print job is complete, the process group work is complete. If the print job is not complete, then at step 185 the media print format is cataloged and the processing unit 138 then returns to process step 180.

If the processing unit 138 determines at process step 180 that there is an RFID transponder to be attached to the next ticket or label to be printed, then the RFID transponder tag 172 is programmed at process 160 and then checked for validity and proper programming at process 162. If the programmed RFID transponder tag 172 is properly verified, a ticket or label is printed at process 181, and then a programmed RFID transponder tag is attached to the printed media sample by operation of the value-adding mechanism 50 at process 186. The processing unit 138 then executes the program step 182 to see if the media needs to be cut, by appropriate action as described above; then, at process step 156, it is checked whether the print job is complete, as also described above.

Responder programming and verification typically occurs prior to media printing so that the smart media with the defect responder tag 170 can be identified by printing a "void" on the media in process 187 rather than printing the normal media format (as in process 181). The ticket or sign printer 168 then typically ejects the defective smart tickets or signs at the media exit 30 and automatically repeats the processes 160 and 162, etc., until a fully functional smart ticket or sign is produced with the appropriate in-line programmed transponder and media format properly printed, in a manner similar to that described in FIG. 7.

In addition, a variation of the embodiment shown in FIGS. 11-15 may be used to construct a transponder (e.g., Motorola BiStatix) by printing a conductive antenna onto a sample of media and then attaching a tag containing an RFID integrated circuit with electrical contacts to the antenna^TMAnd products manufactured by Marconi corporation using Intermec Intellitag * 900MHz or 2.45GHz RFID integrated circuits).

For example, in FIG. 16A, a Motorola-based BiStatix is shown^TMConstruction of the BiStatix label 190 of the integrated circuit 191 on a transparent nonconductive label stock 192: two conductive mounting pads 193 are first fabricated and then mated with the Motorola BiStatix^TMTwo antenna contacts on the integrated circuit 191 are connected. These web-fed BiStatix labels 190 serve as the responder supply web 128 on the ticket or signage printer 168. Two printed conductive carbon antenna sheets 195 can be formed on the ticket or label by selecting the appropriate heat transfer ribbon 16 and non-conductive media 194 during the printing process. The value-adding mechanism 50 can be used to attach the conductive mounting pad 193 on each BiStatix label 190 to two printed conductive carbon antenna sheets 195,to form a complete RFID transponder as shown in fig. 16B. Such an RFID transponder configured in an electrostatically coupled manner can be programmed by appropriately placing the transponder programming antenna 110.

More common magnetically or electromagnetically coupled responders may also be constructed in this manner. In FIG. 16C, the formation of a 2.45GHz Intellitag RFID tag 196 based on an Intermec Intellitag * integrated circuit 197 on a transparent nonconductive label stock 192 is shown: two metal contacts 198 may be connected to two antenna contacts on the Intermec Intellitag * integrated circuit 197. These roll-form Intellitag labels 196 are used as the responder supply roll 128 on the ticket or signage printer 168. By selecting the appropriate heat transfer ribbon 16 and non-conductive media 194 during the printing process, a 2.45GHz conductive silver ink folded dipole antenna 199 can be formed, as shown in fig. 16D. Such a transponder constructed in an electromagnetic link may be programmed by appropriate placement of the transponder programming antenna 110.

The present invention provides several distinct advantages, alone and/or in combination with other techniques. For example, the advantages include the following.

1. The ability to selectively apply RFID transponders to common on-demand printed media samples through program control, thereby converting common labels into "smart" RFID value-added media samples;

2. the ability to selectively fabricate RFID transponders formed by the programmed application of printed antennas and applied RFID integrated circuits to common on-demand printed media samples, thereby converting common labels into "smart" RFID value-added media samples;

3. the ability to provide a single label, ticket, label or plastic card printer capable of producing generic or "smart" RFID media in a desired manner using the same generic label, ticket, label or card;

4. eliminating the need for pre-conversion of RFID smart media that are specifically made by the tag converter and require a user to catalog them, and thus reducing the costs associated therewith.

Other advantages of the present invention include the following.

5. Because the printing of the media is completed before the RFID transponder is embedded or attached to the final media sample, the influence of the 'bumpy' transponder on the printing quality can be avoided when the intelligent media sample is manufactured;

6. the ability to design ancillary alternatives to conventional label, ticket, sign or plastic card printers that enhance the functionality of conventional printers to enable smart labels, tickets, signs or plastic cards to be produced as desired;

7. the ability to enable a single printer to produce either normal or smart media (as smart media is only produced when needed by control of on-demand label format software) is provided on the premise that normal media are employed;

8. a label converter is not needed to provide a special intelligent label reel for an on-demand printer, and the accompanying extra cost of manufacturing and cataloguing special intelligent label materials is avoided;

9. the user is relieved of the need for a separate heat transfer printer to make the smart label;

10. freeing users from reliance on smart tag converters, thereby enabling users to use their existing converters;

11. all the printers in the production line can be designed so that they can produce labels, tickets, signs and cards of the generic type, and labels, tickets, signs and cards of the intelligent type, in an on-demand, program-controlled manner;

12. reducing the daily costs and reducing the complications that prevent the increased production of smart labels on existing conventional label production lines.

Other advantages and benefits are as follows.

As with the above-listed advantages, the present invention enables a truly on-demand customer-specific setting medium, which may be all or any one of them, with a particular type or particular capability of RFID transponder programmed with particular information, which may be pre-printed, or printed at a later date, or not. This means that the end user does not have to install a series of printers or other systems in order to handle the requirements or applications of different customers. The cost savings are significant since the entire roll of unprinted smart labels need not be stored (smart labels may be made of different materials, adhesives, label forms, transponder properties or types). Avoiding investment and maintenance costs of a single purpose production line or equipment. Since the entire process is controlled by a computer program, errors, which are inevitable in, for example, manually converting a normal tag into an RFID tag, can be avoided. Whereby one machine or system can handle all the needs.

In a more general sense, the present invention relates to a method of setting a series of labels, tickets, tags, cards or other media in a desired manner. The method includes providing a series of similar or dissimilar media and attaching, inserting or otherwise connecting one or more non-continuous value-adding elements to a particular media, but not all media, in a desired, selective manner in the series of media. In the preferred embodiment described, the elements are RFID transponders, however, as will be described, other value-adding elements may be incorporated into the selected media.

A third embodiment illustrating the more general nature of the media on-demand style setting process is one application example, as shown in fig. 17-19. With the advent of "large-scale customization" marketing, and the current development and availability of specific customer source data, it is possible to narrow marketing targets to a specific group of customer sources, the well-known characteristics of which are their identity, traits, hobbies, purchasing habits, and other personal characteristics. The present invention has sufficient flexibility to cater to specific future patrons or specific purchasing interests of past customers and other aspects.

In this illustrative hypothetical application, the travel card company wishes to deliver a customer-defined promotional medium to a selected group of customers. Their customers are divided into three groups: green, gold, and platinum card members. The green members are occasional travelers, and in most cases vacations, constitute the group with the lowest membership card usage. The gold member usually uses the member card, mainly for business trip and frequent vacation in the country, and the number of people is less but the utilization rate of the member card is far higher than that of the green member, so that the gold member is the group which most spends money on the travel card company. Platinum members are smaller groups, but the use of the card is 5 times higher than that of gold members every year, and most of the platinum members spend time on international travel and use first-class cabins, luxury hotels and restaurants; they often combine official business and recreational travel, often with spouses or "other important figures". They are highly desirable customers for luxury grades of travel and merchandising companies.

The promotional medium described herein is a customer postcard set 200, consisting of a customer address card and a detachable response piece card, shown in fig. 17A and 17B as a front side 202 of the postcard set and a back side 204 of the postcard set. The group of postcards front 202 is intended to be on-demand printed with the customer's postal address 206 and selected travel promotion offers embodying value-adding elements printed thereon. The reverse side 204 of the group of open wafers 200 is all pre-printed with fixed information: the reverse side of the customer postal address card is printed with the band diagram information 208 for luxury tour a and the band diagram information 210 for luxury tour B; the reverse side of the customer's postal return slip card is printed with the travel card company's return slip address 212 and the business return fee 214. The tablet set 200 may be mechanically folded and sealed so that the customer address 206 and the commercial postage value 216 are displayed during the initial mailing.

Customer specific information and promotional offers are printed on the clear mail piece set front side 202 in a customized manner, including value-adding elements as shown in fig. 18, identifying a particular customer by customer address 206, offering different promotional offers based on different particular customers, and placing the corresponding value-adding elements at 218 and 220. The front side (202) of the postcard group response piece card is 222 for description of luxury tour a and 224 for the corresponding information request field; description of luxury tour B at 226, and corresponding information request field at 228. In addition, for gold and platinum members, there are special print promotional areas that are not printed in an on-demand manner unless special offers are provided to them; the unprinted promotion areas include a promotional area 230 and customer markable reply areas 232 and 234, and a corresponding information request area 228.

In FIG. 18, the value adding element 240-246 is shown. The removable upgradable tour coupon 240 is intended for only green members; the removable level 3 upgradeable coupon 242 is intended for gold and platinum members only; the appropriate coupon will be placed in the tour upgrade offer area 218 on the customer address card. A tag 244 with a permanently attached RFID transponder is placed on the platinum member promotion reservation 238 on the reverse side 204 of all the groups of postcards issued to platinum members (see fig. 17B). The tag 244 contains the address of the particular platinum member, travel record, and card usage information 248 on the responder memory.

The method is characterized in that a global free e-mail service provided by an Internet service provider is printed in advance, the Internet service provider is related to a tourist card company, and only luxury commodity advertisements are made on the Internet. When the platinum member accepts the free e-mail preference, the receipt postcard is sent back to the internet service provider, and the information stored in the memory of the RFID responder tag 244 is wirelessly read and used to automatically establish the world wide email account of the platinum member. Once the responder is disabled, critical customer information, i.e., name and card number, may also be printed on demand onto the customer name and card number field 250.

The removable free flight coupon 246 provides a premium for the Urban Legends helicopter service company, free from main airports to downtown helicopters in New York, Chicago, Paris, and Tokyo. The reservation is only provided to those gold and platinum members who are members of the luxury market who live in any of these 4 cities for a total of more than 15 evenings per year. When appropriate for a given card member, the coupon is placed in a special coupon area 220 on the customer address card.

Consistent with certain characteristics of the manufacturing process, which will be described in detail below, a set of postcards printed in an on-demand manner is completed by selecting a value-adding element, such as that of fig. 18, based on the color of the membership card and the membership travel record, and adding it to each set of postcards issued to green, gold and platinum members. When each member receives the group of open messages, the member takes specific action on the existing removable value-added coupons if it is interested, and marks the customer reply fields 232 and 234 (if any) to indicate acceptance or rejection of the associated promotional offer. The interested member would then send the postage-paid return receipt card back to the travel service to fulfill the requested promotional item.

Returning to fig. 17, if the member is interested in the received information on the luxury tour a, the value-added coupon (240 or 242) provided on the tour upgrade coupon area 218 is removed and placed on the information request area 224. Similarly, information regarding luxury tour B may be requested by removing the removable tour upgrade coupon from preference area 218 and then placing it in information request area 228. If a platinum member decides to accept the free world email service provided on a pre-printed RFID transponder tag 244, a tick mark is placed in the "Yes" box on the printed customer reply field 232 (printing only on the RFID transponder tag 244 attached to the reserved area 238). If the selected gold and platinum member decides to accept the received special free flight coupon 248 from Urban legacy helicopter company, the member removes the coupon from coupon area 220 and places it in coupon area 238, and also checks the box on the printed customer area 236 to check out the city that the member wants to fly free of seat.

Fig. 19 is a top view of an example of a three-stage fabrication process, which embodies exemplary features of the invention in 3 different ways in which a finished set of wafers may be fabricated. Preprinted postcard material 300 is provided that has been printed on the reverse side 208, 210, 212, 214 and 214 of each postcard set 200 (see fig. 17), and has a business postage payment 216 printed on the front side (although printing in this manner may be done on demand). The postcard material 300 passes through a postcard printer 302 that is different from the printer 168 of the second embodiment that uses externally programmed responder tags.

The postcard printer 302 is connected to and driven by a factory controller 306 via a connection 304, the factory controller 306 in turn being connected to a host 301 via a local area network 308, the host 310 comprising a handler 312 and a member database 314. Each specific profile information entered into the member database is screened by the handler 312 and sent to the factory controller 306 via the LAN 308, and further used by the factory control 316 to direct the operation of making each corresponding group of optels 200.

Typically the member's profile in the member database 314 is arranged in order of card number, but since membership changes during use of the card number, the card color is random. For each platinum member profile encountered, a responder label printer 318, equivalent to the printer of the first embodiment of the present invention described above, is commanded by the factory controller 316 via the on-line 320 to produce an RFID responder label 244. Using die cut label supply roll 322 and self-adhesive RFID transponder supply roll 324, transponder label printer 318 produces a continuous length of transponder label tape 326 with programmed RFID transponder labels 244, each of said transponder labels 244 having been pre-printed with a platinum member name and card number and embedded with an RFID transponder with associated member information from database 314. The continuous transponder tag tape 326 with RFID transponder tags 244 is used as an RFID transponder tag supply for the postcard printer 302.

The production operation stage 1 is performed by the post card printer 302 and includes all on-demand printing operations. Since the post card printer 302 is instructed to begin making the group of postcards 200 for each member, the requested member information is transmitted thereto via the connection 304. If green or golden member information is found, only the appropriate customer postal address that should be printed on the front face of the postcard, and the information 222 and 226 for the luxury tours A and B, respectively, are printed on the response piece card on the front face 202 of the postcard group (see FIG. 17). If a gold or platinum member is found to be eligible for a free flight coupon, a customer markable offer reply field 232 is also printed. For all platinum members, sections 206, 222 and 226 are printed with the same content as for gold members, and a customer markable reply section 234 for special life-time email offers is also printed. First checking whether the corresponding RFID transponder tag 244 is in the location to be placed; the RFID transponder tag 244 is then placed on the reserved area 238. Schematic samples of the initial green membership postcard set 328 and the initial platinum membership postcard set 330 as the production of stage 1 are shown in fig. 19.

At stage 2 of the manufacturing process, an additional value-adding process embodying the present invention is used to complete custom setup of a patch of media by appending one or more selected value-adding elements as shown in FIG. 18. In a first value-adding process 332, instructions are made by the production controller 306 via a connection 336 to selectively add the grand 2 tour coupon 240 from the first coupon provider 334 to the group of postcards 200. In a second add-on process 338, instructions are made by the production controller 306 via connection 342 to selectively add the grand 3 tour coupon 242 from the second coupon provider 340 to the group of postcards 200. In the third value-adding process 344, instructions are made by the production controller 306 via the connection 348 to selectively add free flight coupons 246 from a third coupon provider 346 to the group of postcards 200.

An exemplary output of stage 2 is shown as customer set postcard media 350, 352, 354 and 356. The intermediate platinum membership postcard group media 350 is customized to have a free flight coupon 246 in a third add-on process 344; the tour upgrade level 3 coupon 242 is added in the second add process 338; and the RFID transponder tag 244 is assembled at the transponder tag printer 320 by means in the first embodiment of the invention and then placed on the intermediate postcard assembly medium 350 at the postcard printer 302 by means in the second embodiment of the invention. The initial golden membership postcard set 352 is set by the customer in the second add value process 338 to add only the ascending level 3 cruise coupons 242. The middle green member postcard group 354 is set to green members that receive only the level 3 cruise coupon 240 in the first add-on process 332. The intermediate golden member postcard set 356 is configured by the customer to add the cruise upgrade coupon 242 in the second add-on process 338 and to add the free flight coupon 246 in the third add-on process 344.

At stage 3 of the manufacturing process shown in fig. 19, a cut-fold-seal process 358 is used to create a customer-set postcard media for mailing, via line 360, under the control of manufacturing controller 306. The continuous postcard media is cut into individual groups of postcards 200, which are then folded and sealed to expose groups of postcards at their customer addresses on front face 202. A sample of the stage 3 output, the final group of postcard sheets 362, is ejected from the guillotine-fold-and-seal machine 358 onto a finished custom-set postcard media stack 364, as shown.

Some alternatives to the methods and systems shown in fig. 17-19 are contemplated by the present invention. For example, one variation could be that coupons 240, 242, and/or 246 could also be provided with RFID transponders. The transponders on these value-adding elements may be programmed with the same information as the transponder 244 described above. Except that this element, which is modified to be peeled off and then transferred to another portion of the media (and may also be transferred to another separate media), is contained or has a memory therein containing useful information that can be read and utilized wirelessly by a promotional organizer or another interested party.

In addition, chipless RFID transponders may be used instead of RFID transponders with memory. For example, rather than using a responder, i.e., 244, as on the wafer cluster 200 at 238, a series of conductive lines of resonance may be printed on the card. Or other various chipless RFID technologies may be used. One type similar to that shown in fig. 16, namely an integrated circuit tag, may also be used with a printed antenna to form an RFID transponder in situ.

According to exemplary features of the invention, such advertising prints mailed on demand, as depicted in FIGS. 17-19, have the following characteristics:

1) various personalized on-demand printed content on the media is targeted to cater to known hobbies of the target customer;

2) various targeted coupons or other value-adding elements are desirably placed on the media;

3) an RFID transponder containing target customer specific data, such as postcard details, which are sent back and processed for use;

4) printing content on the responder in an on-demand manner that is related to the targeted customer and the stored information;

5) a plurality of value-adding elements are associated not only with the targeted customer, but with each other element to create a coordinated appeal to the specific customer;

6) action reaction items, i.e., transferable coupons, may prompt a particular prospective customer to take personalized action rather than merely a symbolic "yes, i.e.," buy ".

In short, the card may have up to 6, 7 or more on-demand prints, or value-adding elements, which together act to create a strong personalized and complete sales appeal.

However, in another embodiment of certain exemplary features of the present principles, the responder 52 may be programmed with a command that controls the continuous production process, which command may control, for example, the use of another value-adding element on the same media. For example, as a variation of the embodiment shown in FIGS. 17-19 where the value-adding processes 332, 338 and/or 344 are standalone, rather than controlled by the controller 306, the RFID transponder tag 244 can be read and programmed with commands that determine the type, content, or other characteristics of the value-adding elements that are to be applied to the media carrying the transponder tag 244. Additionally, for example, the address material stored on the label 244 can be read at a postage metering station to determine whether postage is correct or not.

Thus, the embodiments shown in FIGS. 17-19 illustrate certain exemplary features of the invention, namely, the ability to configure a range of labels, tickets, tags, plastic cards, postcards or other media as desired, by selectively attaching, inserting or otherwise coupling one or more non-continuous value-adding elements to particular media, but not all media, in the range of media. In addition, it is desirable to perform coherency blending, i.e., the use of one or more items of printed matter on the media and/or value-adding elements, to enable information to be presented to the end user or others in a more flexible manner.

Referring to fig. 20, which illustrates one embodiment of a transponder applicator mechanism 300, under program control, the mechanism 300 encodes and applies RFID transponders to adhesive-backed pre-printed die-cut labels 26 in a selective and on-demand manner. Responder applicator mechanism 300 may be integrated with an existing heat transfer printing mechanism 10 or attached to a heat transfer printing machine as an alternative attachment.

In the embodiment of the invention shown in fig. 20, the printed die cut labels 26 are peeled from the label web 12 by the peel bar 32 and the label web recovery mechanism 34. The printing face of the printed die cut label 26 maintains a substantially straight path along the apertured vacuum guide plate 302 and to the media outlet 30 as it is moved forward by the drive of the pressure roller 20. The slight vacuum force created by the centrifugal fan by expelling air from the enclosed plenum 310 controls the path of the die cut labels 26 without impeding its movement.

When it is desired to make and encode a smart label, RFID transponder 312 is positioned under antenna 314 prior to printing the die cut label. Antenna 314 encodes RFID transponder 312 and checks it with radio signal 316 in the manner described in this application. In the illustrated embodiment, the respondent is adhesive-backed and is supplied in die cut form by an in-line supply mechanism 320 via in-line conveyor belt 318.

Referring to fig. 21, the movement of the platen roller 20 and label web recovery mechanism 34 is stopped when the leading end of the next die cut label 14 is positioned below the print head 18. Likewise, the printed die-cut label 26 continues to move forward under the action of the silicon-driven roller 322, which silicon-driven roller 322 is typically operatively coupled with the drive of the pressure roller 20, but at a surface speed slightly faster than the latter. A silicon driven roller 322 is pressed lightly against the adhesive side of the print die cut label 26 and against a spring loaded nip roller 324.

Assuming that the die cut labels 26 have been properly encoded and collated, when they are in the proper position as they are moved forward, the encoded RFID transponders 312 on the inline web 318 are moved forward by the inline web recycling mechanism 326. When the transponder 312 reaches the highest point of its path on roller 328, linear actuator 330 drives the small roller forward, which presses the encoded transponder 312 against the printed die-cut label 26.

The inline web 318 and the printed die cut labels 26 are both driven forward at the same face speed so that the encoded RFID transponders 312 are peeled off the inline web 318 as they pass over the small rollers 328, as shown in fig. 22. Once the encoded RFID transponder 312 is completely peeled off of the embedded web 318, the linear actuator 330 is retracted while the next uncoded transponder 312 is in position under the antenna 314 for the next round of smart label dispensing.

Referring to fig. 23, forward movement continues until the peeled printed die cut label and encoded RFID transponder laminate (26/312) are delivered to media exit 30. The pressure of the nip wheel, consisting of a silicon driven roller 322, acts on the overlaminate against a spring loaded nip roller 324, thereby permanently joining the peeled printed die cut label-encoded RFID transponder overlaminate (26/312) together.

Responders that failed the verification may (1) be attached to a label printed "void", as described above; (2) if still on the inline belt 318, it is retrieved by the inline belt retrieval mechanism 326; (3) internally disposed of in a trash can. The latter two methods avoid wasting a tag to discard a bad responder.

In addition, one embodiment of a continuous linerless active adhesive medium (i.e., without die cut label web 12) is shown in fig. 24. Here, the pressure roller 20 and the drive roller 322 are both siliceous to prevent the adhesive substance of the labels and responders from adhering to these rollers. The continuous, unguided label material 350 is printed in a similar manner as the above embodiment and is affixed with an encoded RFID transponder 312. However, once the finished labels are delivered to the media outlet 30, an alternative powered cutting device 352 is used to cut the finished unguided labels 354 with or without the attached encoded RFID transponder 312, as shown. The continuous, unguided label material 350 is then retracted to its original printing position under the print head 18.

When a non-reactive adhesive is used (such as the liner material of Appleton active), an alternative retractable actuator 356 is required to activate the non-reactive adhesive along the length of the finished non-oriented label 354 to recover excess media length that results from the finished non-oriented label 354 being fed to the cutting point. Otherwise, the embodiment functions to be comparable to the case where standard, non-oriented material is used as described above.

From the foregoing, it will be observed that numerous modifications and variations can be effectuated by those skilled in the art without departing from the true spirit and novel concepts of the present invention. It is to be understood, of course, that no limitation with respect to the specific embodiments illustrated is intended. The disclosure is intended to include all such modifications as fall within the scope of the claims, when such claims are properly read.

Claims (39)

1. A method of manufacturing a printed medium, comprising the steps of:

moving a plurality of media samples from a media supply to a media outlet;

printing information on the selected media sample;

after printing information on the first surface of the selected one of the media samples, a value-adding element is attached to the selected one of the media samples.

2. The method of claim 1 wherein said value-adding element comprises a radio frequency identification integrated circuit for contacting an antenna structure on said media sample to form a radio frequency identification transponder.

3. The method of claim 1 wherein said value-adding elements comprise radio frequency identification transponders.

4. The method of claim 1, further comprising a checking step in which at least a portion of said radio frequency identification responders are valid.

5. An apparatus for use in connection with a thermal transfer printer, the apparatus comprising a first web, said web enabling a plurality of media samples to be removed from a media sample supply and a print head, said print head being for printing information onto a first surface of said plurality of media samples, said apparatus comprising:

a second web for temporarily removing a plurality of media samples from said first web;

a bonding mechanism, said device bonding a value-adding element to a second surface of said selected one of said media samples after information is printed on said first surface of said selected one of said media samples.

6. The apparatus of claim 5 wherein said value-adding elements comprise an RFID integrated circuit for contacting an antenna structure on said media sample to form an RFID transponder.

7. The apparatus of claim 5 wherein said value-adding elements comprise radio frequency identification transponders.

8. The apparatus of claim 7, further comprising means for verifying that at least a portion of said radio frequency identification responders are valid.

9. The apparatus of claim 5 wherein value-adding elements are attached to a portion of less than all of said plurality of media samples.

10. A method, comprising the steps of:

providing a series of media samples having unnatural or predetermined properties for wirelessly responding to a wireless interrogation signal or electromagnetic field;

inducing a property, or modifying an existing predetermined property, of only selected portions (but not all) of the series of media samples, said property being responsive to a wireless interrogation signal or electromagnetic field.

11. The method of claim 10 wherein said value-adding element comprises a radio frequency identification integrated circuit for contacting an antenna structure on said media sample to form a radio frequency identification transponder.

12. The method of claim 10, said initiating or modifying step comprising inserting, attaching, forming or attaching an RFID transponder to only said selected portion of said series of media samples.

13. The method of claim 12, said RFID transponder being selected from the group of transponders consisting of a chipless transponder, a passive transponder, and an active transponder.

14. The method of claim 10, comprising initiating and modifying electrical characteristics of only the selected portion of the media samples in the series of media samples.

15. The method of claim 14, said selected portion of said series of media samples having a pre-formed characteristic impedance, said causing or modifying step comprising changing said pre-formed characteristic impedance.

16. An article of manufacture comprising a web, tape cassette, or other carrier for transporting a series of labels, tickets, tags, cards or other media, said carrier having different characteristics for selected ones of said media, said selected ones of said media having attached thereto at least one value-adding element.

17. The article of claim 16, said component being a radio frequency identification integrated circuit for contacting an antenna structure on said media sample to form a radio frequency identification transponder.

18. The article of claim 16, said element comprising an RFID transponder or other wireless transponder.

19. The article of claim 18 wherein said media having a value-adding element attached thereto displays a visual indicia indicating whether the responder is defective, invalid, incorrectly programmed, or has another characteristic or attribute.

20. The article of claim 16 wherein said value-adding elements comprise a second media.

21. The article of claim 16 wherein said media having a value-adding element affixed thereto displays text or other indicia indicating the failure or failure of the media or element test.

22. The article of claim 21, the indicia displaying a test result or data or a time stamp.

23. The article of claim 16, the carriers conveying the plurality of media each having different characteristics.

24. The article of claim 16, wherein the carriers carrying the plurality of elements each have different characteristics.

25. The article of claim 16, the carrier supporting the selected media having a plurality of elements.

26. The article of claim 16, the carrier supporting the selected media optionally having different pre-processing and post-processing operations.

27. An on-demand printer for printing information on a series of labels, tickets, tags, cards or other media, comprising:

a media feeder; and

means for attaching non-continuous value-adding elements to a portion of the media (but not all of the media) in a series of such media.

28. The printer of claim 27, said component being a radio frequency identification integrated circuit for contacting an antenna structure on said media sample to form a radio frequency identification transponder.

29. The printer of claim 27 wherein said value-adding element is an RFID transponder or other wireless transponder.

30. The printer of claim 29, further comprising a device in communication with the responder.

31. The printer of claim 30, the communicating step comprising:

(I) testing, identifying, and distinguishing characteristics of the responder,

(II) reading the information stored in the responder,

(III) writing information to the responder.

32. The printer of claim 27 further including means for conditioning said media prior to attachment of said value-adding element to said selected media.

33. The printer of claim 32, wherein the processing device comprises a printing device.

34. The printer of claim 33 wherein said value-adding element is an RFID transponder or other wireless transponder and said printer or printing accessory includes means for communicating with said transponder.

35. The printer of claim 34, said printing device being responsive to said means for communicating and printing a result of said communicating with said responder.

36. The printer of claim 34, said printing device being responsive to said means for communicating and printing an indicia indicative of a defect or another characteristic or attribute of said responder.

37. Apparatus for applying a selected component to a selected label, ticket, label, card or other medium, at least one of the component and the medium being adhesive-backed and carried on a carrier, comprising:

means for stripping said one element or medium from its carrier;

means for supporting the stripped elements or media;

means for bringing said supported element or medium into a position adjacent to another of said elements or media;

means for pressing the element and media together.

38. The apparatus of claim 37, said means for pressing comprising a compaction ram.

39. The apparatus of claim 38, the compaction tamper comprising:

a fast acting solenoid;

a gas spring driven by said solenoid;

a pressure applying mechanism coupled to said gas spring, said mechanism defining a surface for pressing said medium and said element together, said gas spring damping the rapid action of said solenoid.