HK1080589B - Laser imageable rfid label/tag - Google Patents

Description

Laser imageable RFID tag/label

Technical Field

The present invention relates to the field of Radio Frequency Identification (RFID) tags (tags) and labels (labels), and more particularly to specific structures for RFID tags and labels, and methods of making the same.

Background

RFID systems are comprised of many components including tags, hand-held or stationary readers, data entry units, and system software. Tags are an integral part of this technology and come in a variety of shapes, sizes and reading ranges, including thin and flexible "smart labels" that can be laminated between paper or plastic.

RFID creates an automated way to collect information about a product, location, time, or transaction quickly, easily, and without human error. It provides a contactless data link that does not require line of sight or worry about harsh or dirty environments that limit the use of other automatic ID technologies, such as bar codes.

In addition, RFID is not just an ID code, but can be used as a data carrier, where information is dynamically written on a tag or updated.

RFID has found hundreds of applications in tens of basic industries. RFID is now used in many applications, such as vehicle and personnel access control, automatic theft prevention systems, product and asset tracking, and supply chain automation. Other applications include payment and loyalty, personal and vehicle and personnel access control, car security, product and asset tracking, sports timing, livestock identification, document management and supply chain automation.

In one application, RFID is used as part of a gas station payment system that uses radio frequency signals to wirelessly communicate in both directions between a key ring tag and a reader on a gasoline pump or workstation. The desired purchase is automatically charged from the gas station customer's credit card option without swiping a credit card or paying the attendant.

Prior art RFID tags and labels are typically in roll form. Some such tags and labels include an image on their surface. These images are typically formed using thermal transfer or direct heating techniques. This technique is preferred because the RFID circuit is not exposed to undue stress, such as pressure or heat. However, there is a portion of the durable commercial wholesale market where shipping labels are printed in bulk by laser printers. Unlike thermal transfer techniques, laser printing exposes the entire media to pressure and heat. In this and other applications, it is desirable to be able to batch print tags or labels with RFID capabilities. There is a strong need in the art for imageable RFID tags or labels that utilize laser printing.

Disclosure of Invention

It is a general object of the present invention to provide an imageable RFID tag (tag) or label (label) using laser printing without damaging the RFID circuitry. It is another object of the invention to provide a method of manufacturing such an RFID tag or label.

To achieve these goals, RFID tags or labels are produced with customized variable embossing (imprinting). Sheets of paper are used to form a simple, inexpensive structure for a transponder (transponder) that supports and protects the RFID. The paper structure may also serve as a surface for customized variable imprinting using a laser printer. The structure includes a bottom layer; the top layer, on which the laser printer printed image is formed by passing the sheet assembly through the print path of a laser printer; and a masking sheet having at least a window, the sheets forming a protective pocket within the window to protect the electronic circuitry from heat and pressure generated by the laser printer when printing the image on the top sheet. After printing, the structure is separated into a plurality of RFID tags or labels. The identification information is transmitted from the electronic circuit within the protective case to an external receiver.

Drawings

Figure 1 shows a perspective view of a laser printer and sheet assembly before and after it has passed through the printer.

FIG. 2 is a schematic longitudinal cross-sectional view of the "protective case" area of an RFID tag or label.

Fig. 3 is a top plan view of the face (face) of an RFID tag or label sheet assembly.

Fig. 4 is an exploded perspective view of a sheet assembly of an RFID tag or label.

Detailed Description

While the specification describes particular embodiments of the present invention, various modifications can be made by those skilled in the art without departing from the inventive concept.

The present invention provides an economical and convenient method for producing Radio Frequency Identification (RFID) tags or labels with customized variable imprinting. Standard sheets of paper can be used to form a simple, inexpensive structure that supports and protects the RFID transponder. At the same time, the paper structure may also serve as a surface for customized variable imprinting using a versatile and inexpensive laser printer.

Figure 1 shows an imageable electronic identification sheet assembly 11 of the present invention before and after it is fed into a laser printer 13. The laser printer prints an image 33 onto the sheet assembly 11. Each imageable electronic identification sheet assembly 11 is formed of a bottom layer 15, a top layer 17, and a masking sheet 19 (see fig. 2 and 4). The mask sheet 19 has one or more windows 21 formed therein. Four windows are shown in the exploded perspective view of the RFID tag or label sheet assembly of figure 4.

A mask sheet 19 is attached between the bottom sheet 15 and the top sheet 17 to form one or more protective pockets. In the particular embodiment shown in fig. 4, four windows 21 form four protective pockets 23. Within each protective pocket 23 are one or more electronic circuits 25. Each electronic circuit 25 may be completely housed within a protective case. In addition to fig. 4, a schematic longitudinal cross-sectional view of the "protective case" area of the RFID tag or label of fig. 2 is shown illustrating a single electronic circuit 25 within each protective case 23. For example, the electronic circuit 25 may be an RFID transponder circuit, such as Texas instruments (TEXAS INTERRUMENTS)HF-I transmits one of a Transponder insert (Transponder Inlay) series.

The unique protective pocket 23 protects the electronic circuit 25 from the heat and pressure generated by the laser printer 13 when printing an image on the top sheet 17. The walls of the window 21 forming the mask sheet 19 absorb a portion of the pressure exerted by the feed rollers of the laser printer 13. The bottom layer 15 and the top layer 17 also help to distribute some of the pressure on the electronic circuit 25. In addition to the protective pocket 23, the bottom layer 15 and the top layer 17 also serve to isolate and conduct away the heat of laser printing from the electronic circuitry 25.

Inside the protective box 23 is a transmission device 27 for transmitting identification information 29 from the electronic circuit 25 to an external transceiver 31 (transmitter) outside the protective box 23. The transmission device 27 may be a helical antenna portion of the electronic circuit 25 shown in fig. 2 and 4. The electronic circuit 25 comprises a microchip 35 electrically connected to the transmission device 27.

The base layer 15, top layer 17 and masking sheet 19 may be of any size that can be fed into a laser printer, however, 8¹/₂A x 11 inch, a-4, or other standard size paper is desirable because of the lower cost and greater compatibility of standard printers and software packages used to design the images 33 printed by laser printers.

The entire sheet assembly 11 should have a thickness such that it is suitable for printing the image 33 by the laser printer 13. For the case of using a standard laser printer, a thickness of one sheet assembly of less than fifteen thousandths of an inch, i.e., 15 mils, is generally suitable for feeding into the laser printer. The sheet assembly is formed with a permanent adhesive (adhesive)37 to adhere the base sheet 15 to the mask sheet 19 and the electronic circuitry 25. In one particular embodiment, the electronic circuit 25 is formed on a mounting sheet 39, and the mounting sheet 39 is adhered to the backsheet 15 with a permanent adhesive 37. The mounting sheet 39 may be made of polyester. The sheet assembly may be bonded together using rubber or other types of adhesives.

For example, the bottom and top layers 15 and 17 may be 20 pound bond paper, while the mask sheet 19 may be 60 or 80 pound bond paper. The window 21 may be about 6cm x 8 cm. The thickness and window size of these papers are suitable to protect the electronic circuit 25 from the pressure and heat of the laser printer. Of course other sheet thicknesses and window sizes may be used for the electronic circuits 25 of different footprints (footers) and for different laser printers. The bottom layer 15 and the top layer 17 may also have a thickness in the range of about 3 to 4 mils, while the mask layer 19 may have a thickness in the range of about 3 to 8 mils, preferably 6 mils. The thickness of the layers of adhesive 37 that bond the bottom layer 15 and the top layer 17 to the mask sheet 19 and the electronic circuit 25 to the bottom layer may be about 1 mil. The electronic circuit may be 6 mils or slightly larger to fit into the protective pocket 23. However, the height of the electronic circuit may vary in different embodiments. For example, if thinner paper is used for the bottom and top layers 15, 17 and thicker paper is used for the mask sheet 19, taller electronic circuitry can be used to keep the sheet assembly thin enough to pass through the laser printer 13. Similarly, the use of a thinner mounting sheet 39, or no mounting sheet 39 at all, allows for a greater height within the protective pocket 23 to allow for a taller electronic circuit. In some embodiments, the height of the electronic circuit 25, with or without the use of the mounting sheet 39, may be greater than the height of the protective pocket 23. In such a case, the top layer 17 or the bottom layer 15 may protrude slightly outward. Alternatively, a portion of the top layer 17 may be hollowed out to accommodate the microchip 35.

In one embodiment, the sheet assembly 11 is assembled by applying the adhesive 37 to the base sheet 15 and then adhering the mask sheet 19 to the base sheet 15. The window 21 is typically cut from the mask sheet 19 prior to assembly of the sheet assembly 11. The electronic circuit 25 is then inserted into the window 21 using a label applicator. Alternatively, the electronic circuit 25 may be adhered to the substrate 15 and then the mask sheet 19 is adhered to the substrate 15 with the window 21 placed around the electronic circuit 25. In any case, the footprint of the cross-section of the electronic circuit 25 may be made suitable for placement within the window 21. Adhesive 37 may then be applied to the top layer 17 and/or the mask sheet 19, and the top layer 17 adhered to the mask sheet 19 so that the electronic circuit 25 is completely enclosed within the protective pocket 23. A non-adhesive area 41 is formed on the inner surface of the top sheet 17 so that the adhesive does not contact the microchip 35. In this way, the electronic circuit 25 adheres to the bottom layer 15 and not to the top layer 17. In other embodiments, the electronic circuit 25 is adhered to both the bottom layer 15 and the top layer 17 or only the top layer 17. The electronic circuit 25 may also be placed in the protective case 23 without fixing the electronic circuit 25 using any adhesive.

In the embodiment shown in figures 1 and 4, using a plurality of protective boxes 23 having a plurality of electronic circuits 25, measures are taken to separate the sheet assembly 11 into a plurality of sub-assemblies 41, each sub-assembly 41 comprising one protective box containing an electronic circuit 25, thereby producing individual RFID tags or labels. For this purpose, the sheet assembly 11 may comprise a separation line 43. For example, the separation line 43 may be cleanly die cut, or may include cuts (cuts) and spaces (tie). After the bonding step, the separation lines 43 may be cut into the sheet assembly 11. In the embodiment of figures 1, 3 and 4, a vertical and a horizontal separation line 43 is cut from the top layer 17, the masking sheet 19, and through to the bottom layer 15 to divide the sheet assembly into 4 sub-assemblies, each having a protective pocket 23 containing an electronic circuit 25.

The completed sheet assembly 11 may then be fed into the printer 13 of fig. 1 as described above to provide customized variable embossing on the top sheet 17. The laser printer 13 may print images on the sheet assembly 11 such that each sub-assembly 41 has an image that is the same or different from the other sub-assemblies 41. Figure 3 is a plan view of an upper surface of the sheet assembly 11 after passing through the laser printer 13. Each subassembly 41 has a different image printed thereon. In the example given, the subassembly 41 is intended for use on the dashboard of a vehicle, each with a different vehicle printed thereon. The specific design printed on the sheet assembly 11 may be controlled by a computer connected to the laser printer 13.

After printing, the sheet assembly 11 is separated along separation lines 43 to form a plurality of laser embossed RFID labels or tags. In particular the manufacture of the label may be achieved by adding an additional step to the above-described gluing step. A further adhesive layer may be added to the outside of the bottom layer 15, together with a liner layer covering the further adhesive layer. Thus, after separation of the laser imprinted RFID label, the liner layer may be removed to expose the adhesive layer and the label may be adhered to a desired object. Alternatively, an adhesive layer and a liner layer may be attached to the top layer 17.

The external transceiver 31 illustrated in fig. 2 may include an antenna and a reader as is well known in the art. The external transceiver 31 may also comprise a single transmitter, receiver and reader. The external transceiver 31 sends a command 45 to the electronic circuit 25 and receives a response 29 from the electronic circuit 25. The electronic circuit acts as a transponder. The response from the electronic circuit 25 may be identification information. The identification information is stored in the microchip 35 and may be an ID code, or the microchip 35 may be used as a data carrier to dynamically write information to the microchip 35 and update information on the microchip 35. Advantageously, the microchip 35 may be a passive device such that it does not require a battery, which would increase the size and weight and shorten the life of the RFID tag or label. However, in other embodiments it may be desirable to have a battery or other power source carried with the chip.

The RFID tags or labels of the present invention may have a variety of applications. For example, RFID tags or labels may be used as part of a payment system. The reader of the external transceiver 31 may communicate with a database of identification information and respond to the user's information so that payment between the user and the payment system may be made.

The RFID tags or labels of the present invention may also be used as part of a security system having an indicator to notify security personnel when the external transceiver 31 receives identification information from the RFID tag or label.

The RFID tags or labels of the present invention may further be used in systems such as product authentication, ticketing, library management and supply chain management applications by utilizing RFID tags or labels to transmit identification information to the system.

In another application, the RFID tags or labels of the present invention may be used as shipping labels or labels that correspond to the laser printer printed image on the goods and the identification information provided by the microchip 35.

It should be understood that the RFID tags or labels of the present invention are not limited to operation in the radio frequency range. They may also operate using other electromagnetic frequencies. In addition, they may communicate between the protective box 23 and the external transceiver 31 using sound or different types of transmission (radiation). The present invention may also utilize additional laminae other than the three described herein. For example, 4 or more layers of paper may be used. Further, the present invention may utilize materials other than paper to form the sheet assembly 11. For example, a thin layer of plastic may be used instead. The invention is also not limited to the use of laser printers. Other types of printing such as ink jet, dot matrix or web printing may be used instead, and the protective cartridge 23 may still be used to protect the electronic circuit 25. Also, the electronic circuit 25 may be placed in the protective case 23 in an orientation other than the above-described orientation.

It is to be understood that other embodiments may be utilized, and structural and functional changes may be made without departing from the scope of the present invention. The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Accordingly, many modifications and variations are possible in light of the above teaching. The scope of the invention is not limited by this detailed description.

Claims (33)

1. A method of forming a printable electronic sheet assembly, the method comprising the steps of:

forming a thin-layer assembly having an upper layer, a lower layer, and an intermediate layer of ink-receptive paper material, wherein the intermediate layer has at least one opening therein to receive an electronic circuit having a height equal to or less than the thickness of the intermediate layer;

bonding the three layers together to form a flexible lamina having a thickness of less than fifteen thousandths of an inch; the size of the thin layer assembly is 8¹/₂X 11 inch or A-4 paper;

printing on the sheet assembly with a printer that subjects the sheet assembly to heat and pressure;

cutting said thin-film assembly into a reduced-size multi-layer assembly, each assembly including at least one of said electronic circuits; and

subsequently applying a high frequency RF signal to the reduced size assembly;

wherein said electronic circuit is inserted into said at least one opening using a label applicator; and

wherein the inner surface of the upper layer or the inner surface of the lower layer does not carry at least one electronic circuit and at least one antenna.

2. An imageable electronic identification sheet assembly comprising:

a bottom layer;

an ink-receptive top layer on which an image printed by a laser printer is formed by feeding a sheet assembly along a print path of the laser printer or an ink-jet printer;

a mask sheet having a window formed therein, the mask sheet being connected between the bottom layer and the top layer to form a protective case within the window for protecting an electronic circuit fully connected within the protective case from heat and pressure applied by a laser printer or an ink jet printer when printing an image on the top layer;

a transmission device located inside the protective box for transmitting identification information from the electronic circuit to an external receiver outside the protective box; and

the sheet assembly exhibits a thickness equal to or less than 0.015 inches for reliable delivery through a printing press;

wherein the inner surface of the bottom layer or the inner surface of the top layer does not carry at least one electronic circuit and at least one antenna.

3. The sheet assembly of claim 2, further comprising additional windows on the mask sheet forming a protective pocket to protect additional electronic circuits fully connected within the protective pocket.

4. The sheet assembly of claim 3, further comprising separation lines formed on the sheet assembly to divide the sheet assembly into a plurality of sub-assemblies, wherein each sub-assembly includes a protective pocket containing electronic circuitry.

5. The sheet assembly of claim 4, wherein the separation lines are die cut.

6. The sheet assembly of claim 2, wherein

The transmission device is an antenna forming part of the electronic circuit.

7. The sheet assembly of claim 2, wherein

The footprint of the cross-section of the electronic circuit is such that it fits within the window of the mask sheet.

8. The sheet assembly of claim 2, further comprising a permanent adhesive connected to the mask sheet and the bottom layer of the electronic circuit.

9. The sheet assembly of claim 2, further comprising a permanent adhesive attached to the top layer of the mask sheet.

10. The sheet assembly of claim 8, further comprising an adhesive on an outer surface of the sheet assembly to adhere the sheet assembly to an object as a label.

11. The sheet assembly of claim 2, wherein the sheet assembly is less than one inch thickIs fifteen thousandths of a thousand and is 8¹/₂X 11 inches or a-4 paper size to feed into the laser printer.

12. The sheet assembly of claim 2, wherein the bottom and top sheets are 20 pound bond paper.

13. The sheet assembly of claim 2, wherein the mask sheet is formed of 60-80 pound bond paper.

14. The sheet assembly of claim 2, wherein the electronic circuit is a radio frequency identification transponder.

15. The sheet assembly of claim 14, wherein the radio frequency identification transponder is a passive device.

16. The sheet assembly of claim 4, wherein each of the subassemblies is a shipping label and the laser printer printed image and the identification information correspond to goods.

17. The thin layer assembly of claim 2, wherein the transmission device within the protective box can transmit electromagnetic radiation, the electromagnetic radiation being radio frequency waves.

18. A method of forming an image formable electronic identification sheet assembly comprising the steps of:

attaching at least one electronic circuit to a protective pocket of a sheet assembly formed by joining a bottom sheet, a paper top sheet of ink-receptive material, and a mask sheet having at least one window therein for framing said electronic circuit, said sheet assembly having a thickness equal to or less than fifteen thousandths of an inch;

printing on the sheet assembly using the laser or inkjet printer, wherein the sheet assembly is subjected to heat and pressure generated by the laser or inkjet printer; and

subsequently communicating with the electronic circuit within the protective case using electromagnetic radiation to obtain identification information;

wherein said electronic circuit is inserted into said at least one window using a label applicator; and

wherein the inner surface of the bottom layer or the inner surface of the top layer does not carry at least one electronic circuit and at least one antenna.

19. The method of claim 18, further comprising the step of connecting additional electronic circuitry to additional protective pockets formed by additional windows in the mask sheet.

20. The method of claim 18, further comprising the step of passing the sheet assembly through the print path of a laser printer and printing an image to be printed by the laser printer on the top layer.

21. The method of claim 20, further comprising the step of communicating with a receiver outside the protective pocket using electromagnetic radiation transmitted by a transmission portion of the electronic circuit inside the protective pocket.

22. The method of claim 19, further comprising forming separation lines in the sheet assembly for dividing the sheet assembly into a plurality of subassemblies, wherein each subassembly includes a protective pocket containing electronic circuitry.

23. The method of claim 22, further comprising the step of die cutting the separation line.

24. The method of claim 22, further comprising the step of dividing the sheet assembly into a plurality of subassemblies along the separation lines.

25. The method of claim 22, further comprising the step of dividing the sheet assembly having the laser printer printed image into a plurality of subassemblies by dividing the sheet assembly along the separation lines.

26. The method of claim 25, wherein each of the subassemblies has a laser printer printed image formed as the sheet assembly passes through the print path of a laser printer, and the laser printer printed image is printed on the top layer.

27. The method of claim 18, wherein the step of attaching at least one electronic circuit to the protective case further comprises the step of placing a permanent adhesive on the bottom layer, the top layer, the mask sheet, and at least one electronic circuit.

28. The method of claim 27, wherein the step of attaching at least one electronic circuit into the protective pocket further comprises the step of attaching the electronic circuit to the substrate using a permanent adhesive.

29. The method of claim 27, further comprising placing an adhesive on an outer surface of the sheet assembly to adhere the sheet assembly to an object as a label.

30. The method of claim 18, further comprising the step of communicating with a receiver outside the protective pocket using electromagnetic radiation transmitted by a transmission portion of the electronic circuit inside the protective pocket.

31. The method of claim 18, further comprising the step of receiving the identification information at an external receiver external to the protective case.

32. The method of claim 18, wherein the communicating step is accomplished by transmitting electromagnetic radiation from a transmitting device external to the protective case to the electronic circuit, energizing the electronic circuit with the electromagnetic radiation, and transmitting the identification information from a transmitting portion of the electronic circuit to a receiver external to the protective case.

33. The method of claim 18, wherein the electromagnetic radiation is radio frequency waves.