Abstract:
The present invention describes an RFID tag and a method of making an RFID tag. The RFID tag can include a first substrate with a conductive layer disposed thereon. Further, the RFID tag can be formed with a second substrate that can have any number of components, for example a strap, a processor, a blade and a coupling mechanism mounted thereon. Also, the second substrate can be coupled to the first substrate with a coupling mechanism.

Description:
FIELD OF THE INVENTION 
     The present invention is in the field of radio frequency identification (RFID) device manufacturing. 
     BACKGROUND OF THE INVENTION 
     The use of radio frequency identification (RFID) to identify one of a plurality of items is well known. Typically RFID Tags consist of a semiconductor device, formed in one or more materials such as an organic semiconductor, for example a doped polyanyline, an inorganic semiconductor such as doped amorphous silicon or a doped crystal silicon, and an antenna, capable of receiving energy in the near field, far field or both. 
     The semiconductor circuit performs functions such as the rectification of energy from a reader device to provide some or all of the power for the device, receive circuits to accept commands from a reader system if required, a logic circuit to store an identification code and a method of sending information back to a reader, such as varying the semiconductors impedance presented to the antenna, typically described as backscatter modulation. The above described device is commonly described as an RFID chip. The RFID Chip maybe directly attached to the antenna or attached via an electric field coupling, a magnetic field coupling or a combination of both. Alternatively, the RFID Chip may be first attached to a structure having two or more electrical leads, which is then attached to an antenna by either direct connection, an electric field coupling, a magnetic field coupling or a combination of both. This is typically referred to as a “strap” or “interposer”. The RFID Chip stores data, which can include identifying data unique to a specific item, which is accessed by a device commonly described as a reader or interrogator. 
     RFID tags can be attached to items for inventory control, shipment control, and the like. RFID tags are particularly useful in identifying, tracking and controlling items such as packages, pallets, and other product containers. The location of each item can be tracked and information identifying the owner of the item or specific handling requirements, can be encoded into the RFID tag and accessed by a reader in a suitable location, such as a portal for taking goods in and out of a building, or by a hand-held device. 
     RFID tags have been incorporated into a pressure sensitive adhesive-backed label for items contained in temporary packaging, such as cardboard cartons, or containers which are to undergo a number of reuses, such as pallets, waste containers, shipment containers and the like. These labels are fabricated by attaching an antenna made of metal foil or other suitable material to a substrate material such as paper, film and the like, also referred to as an inlay substrate. 
     Construction of an RFID device can include an RFID chip or strap that is attached to the substrate in cooperative disposition with the antenna to form what is typically referred to as an RFID tag inlay. Exemplary RFID inlays are available from Avery Dennison RFID Company of Clinton, S.C. and sold under the trade designation “AD” followed by a model or part number. An adhesive is then applied to the surface of the inlay substrate over the antenna and RFID chip, and the inlay substrate may then be attached directly to a substrate or article or may be made or incorporated into a label substrate, on which text and graphics can be imprinted, so that the adhesive, antenna and RFID chip are sandwiched between the inlay substrate and the label substrate. A layer of adhesive is then applied to the surface of the label substrate over the inlay, followed by the addition of a release layer over the adhesive to form a laminate. 
     The laminate can then be die cut to the finished label size. Printing of a bar code or other information, text and graphics onto the finished label, and coding of the RFID Tag can take place before or after the die cutting step. The labels are then wound tightly onto a spool or processed into a fan-fold configuration for shipment to a customer or return to the electronic manufacturer or marketer. The application of the inlay to the paper is usually carried out by an electronic manufacturer and the remaining steps are typically carried out by a label manufacturer. 
     Traditionally, RFID tags are produced as self-contained devices, including both a strap and antenna, where the antenna is a significant cost in the assembly. Additionally, effective coupling of the antenna and the strap must be achieved for the RFID tag to be operable. That is, specific antennas are designed for particular end use applications. This requires a great deal of precision due to the relative size of the components and may also lead to a large inventory in order to accommodate the demands of a broad customer base. Furthermore many RFID tags are permanently affixed to particular items and cannot be recovered for reuse. 
     BRIEF SUMMARY OF THE INVENTION 
     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
     One exemplary embodiment of the invention describes an RFID tag. The RFID tag can include a first substrate with a conductive layer disposed thereon; and a second substrate that can have a strap, containing a RFID chip, a cutting device, such as a blade and a coupling mechanism mounted thereon, where the second substrate can be coupled to the first substrate with a coupling mechanism. 
     Another exemplary embodiment can include a method of forming an RFID tag. The method can include steps for mounting a conductive layer on a first substrate; mounting a blade, a strap, containing a RFID Chip on a second substrate; pressing the second substrate against the first substrate; cutting the first substrate and the conductive layer with the blade on the second substrate to form an antenna; and anchoring the second substrate to the first substrate. 
     In yet another exemplary embodiment, a package is provided having a conductive material provided on at least a portion of the package, a RFID intermediate is provided having a cutting device, strap leads and an integrated circuit or chip, the RFID intermediate is pressed against the conductive layer on the package such that the RFID intermediate is brought into operative contact with the conductive layer forming an RFID device integral with the package. 
     The cutting or steps of pressing or engaging the RFID device into operative association with the substrate creates a shaped configuration that forms a particular antenna adapted to serve a specific application. 
     Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description of the various embodiments and specific examples, while indicating preferred and other embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which: 
         FIG. 1  shows an exemplary substrate; 
         FIG. 2  shows an exemplary view of an RFID device; 
         FIG. 3  shows an exemplary perspective side view of an RFID tag applied to a substrate; 
         FIG. 4  shows an exemplary perspective back view of an RFID tag applied to a substrate; 
         FIG. 5  is another exemplary view of an RFID device; and 
         FIG. 6  is another exemplary front view of an RFID tag applied to a substrate. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments can be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows. 
     The word “exemplary” is used herein to mean “serving as an example, instance, or illustration”. Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the invention” does not require that all embodiments of the invention include the discussed feature, advantage or mode of operation. 
     Generally referring to  FIGS. 1-6 , an RFID device and method of applying the same to a substrate is disclosed. The RFID device can be manufactured using any of a variety of processes, for example a pre-conversion process that is an antenna is formed and then an RFID device can be attached to the antenna at a later date. The RFID device can further include a paper web onto which a variety of items, such as human and machine-readable indicia can be printed. The RFID tag can further be formed using a polyethylene terephthalate (PET) material such as with a RFID inlay in which a chip or strap is placed on an antenna that is disposed on the PET substrate. 
       FIGS. 1 and 2  show exemplary embodiments of a substrate and a RFID device.  FIG. 1  shows a side view of an exemplary substrate  100 . Substrate  100  can have a front wall  102  and a back wall  104 . Between the front wall  102  and back wall  104  there can be a filler material  106 , for example corrugated material. Other suitable substrates may include a foam core, paperboard, Substrate  100  can be any of a variety of materials, for example corrugated cardboard, plastic, foam core board, PET, paperboard or the like. A section of conductive material  108 , for example aluminum foil, copper, conductive ink or the like, can be incorporated into substrate  100 , for example on the interior of front wall  102 . The conductive material  108  can take any shape or form. The conductive material can also include a particular logo, design, trademark or trade name of a customer, user or the like or can form part of the sealing, securing mechanism for the package or other utilitarian feature. 
       FIG. 2  shows an RFID device  200 . RFID device  200  can be made of an outer substrate  202  and a cutting mechanism such as a blade or sharp or hardened edge  204 . Outer substrate  202  can be made of a variety of materials, for example a hard plastic, reinforced or stiffened paperboard. Blade  204  can have an upper point  206  and a lower point  208 , and can be shaped in a variety of forms. In one exemplary embodiment upper point  206  can be a proximal end and lower point  208  can be a distal end of blade  204 , and arranged substantially parallel to substrate  202 . Reactive RFID strap  210  can be included within outer substrate  202 . RFID device  200  can have locking mechanisms  212  placed in a number of suitable locations. The locking mechanisms  212  can form anchor tabs that can be inserted into the package or substrate and prevent the RFID device  200  from being removed without. 
       FIGS. 3 and 4  show exemplary embodiments of an RFID device applied to a substrate that together can form an RFID tag.  FIG. 3  shows a side view of an exemplary assembly of a coupled RFID tag  300 . Substrate  302  can have both front wall  304  and back wall  306 . Between front wall  304  and back wall  306  there can be a filler material  322 , for example corrugated material, foam or air cells. Substrate  302  can be any of a variety of materials, for example corrugated cardboard, plastic, foam core board, PET, open celled paperboard or the like. A section of conductive material  308 , for example aluminum foil, can be incorporated into substrate  302 , for example in the interior of front wall  304 . 
     An RFID device, such as previously discussed with respect to  FIG. 2 , can include blade  310  and outer substrate  312 . Outer substrate  312  can be made of a variety of materials, for example a hard plastic. Blade  310  can have an upper point  318  and a lower point  316  and can be shaped in a variety of forms. In one exemplary embodiment upper point  318  can be a proximal end and lower point  316  can be a distal end of blade  310  and arranged substantially parallel to substrate  312 . Reactive RFID strap  314  can be included within outer substrate  312 . 
     Still referring to  FIG. 3 , an RFID tag can be formed by placing an RFID device in a location above a top edge of conductive material  308  which can be within front wall  304 . The RFID device can be pressed into front wall  304 . Blade  310  can penetrate front wall  304 , conductive material  308  and filler material  322 . Blade  310  can cut out or other wise remove a shaped section of the conductive material  308  and filler material  322 , similar to for example a cookie cutter which removes a particular shape or pattern of dough. The shaped section can form an antenna for an RFID tag having a predetermined configuration for the particular application for which the antenna is to be used with. Any cut sections of conductive material  308  and filler material  322  can be forced backwards into substrate  302  to create the shaped section. The cut sections can be retained or can be removed by suitable means, for instance a vacuum, peeling away the material, mechanical picking or such other means as may be appropriate. Locking mechanisms  320  can anchor the RFID device to the filler material  322  of substrate  302 . Reactive strap  314  can be cooperatively disposed with respect to blade  310  (and hence an antenna formed after blade  310  is applied to substrate  302 ) so that reactive strap  314  can couple with the formed antenna in a manner that can make an RFID inlay. 
     The exemplary RFID tag of  FIG. 3  can be used for a variety of applications, including tracking and controlling packages and inventory. Furthermore an RFID device can be recovered from the waste chain after an initial use, for example by removing an RFID device from the used substrate. The RFID device can then be recycled, for example by reprogramming the RFID Chip and reused. 
       FIG. 4  shows an exemplary back view of the exemplary embodiment described above in  FIG. 3 . Blade  402 , for example a cutting blade, can have an upper point  410  and a lower point  412  and can be shaped in a variety of forms. In one exemplary embodiment, upper point  410  can be a proximal end and lower point  412  can be a distal end of blade  402 , and arranged substantially parallel to outer substrate  412 . Blade  402  can be compressed through front wall  414 , for example penetrating any of front wall  414 , conductive layer  408 , and filler material  416 . The shaped section can form the antenna for an RFID tag. Blade  402  need not penetrate back wall  400 . Upper point  410  of blade  402  can be above the top edge of conductive material  408 . Blade  402  can be attached to outer substrate  412 . Outer substrate  412  can include reactive strap  404 . Outer substrate  412  and thus reactive strap  404  need not penetrate front wall  414 . Reactive strap  404  can be cooperatively disposed with respect to blade  402  (and hence the formed antenna) so that reactive strap  404 , and thus RFID Chip  406  can couple with the formed antenna in a manner that can make an RFID tag operative at a longer range than the cutting device could achieve on its own. 
     An exemplary RFID tag, such as that shown in  FIG. 4 , can be used for a variety of applications, including tracking and controlling packages and inventory. Furthermore an RFID device (which can be blade  402  and outer substrate  412 ) can be recovered from the waste chain after an initial use, and can be recycled and reused. 
       FIGS. 5 and 6  show additional exemplary embodiments of an RFID device and a substrate on which the RFID device can be applied.  FIG. 5  can include an RFID device  500 . RFID device  500  can have an upper half  502  and a lower half  504 . Upper half  502  and lower half  504  can be made of any of a variety of materials, for example hard plastic. Upper half  502  and lower half  504  can be joined at hinge  506 . Hinge  506  can operate to bring upper half  502  into contact with lower half  504 . Upper half  502  and lower half  504  can close flush against one another, allowing an RFID device to fasten together. An RFID device can be coupled together by any of a variety of means, for example, a clip, clasp, spring, anchor, chemical coupling, or the like. When closed, RFID device  500  can be shaped in any of a variety of forms, for example a sphere, cylinder, cube or the like. 
     RFID device  500  can also have blade  508 , for example a cutting blade. Blade  508  can extend from either upper half  502  or lower half  504  or both. Upper half  502  and lower half  504  can be clipped together such that blade  508  does not interfere with the complete closure of RFID device  500 . For example, the half opposite blade  508  can include a hollow space or recess where blade  508  can be housed if upper half  502  and lower half  504  of RFID device  500  are coupled together. RFID device  500  can also house strap  510  and semiconductor device  512 . Strap  510  and semiconductor device  512  can be housed in either upper half  502  or lower half  504  or may extend between the sections. 
     Referring now to  FIG. 6 , an exemplary embodiment of an RFID tag  600 , which can be composed of an RFID device  604  clipped to a substrate  602 . Substrate  602  can be made of any of a variety of materials, for example a paper ticket used in retail applications. Substrate  602  can include a layer of conductive material, for example aluminum foil, copper, conductive ink or the like. RFID device  604  can be formed of two halves. The two halves can be made of any suitable material, for example hard plastic. RFID device  604  can include blade  606 , for example a cutting blade. Blade  606  can have an upper blade point  608 . RFID device  604  can be coupled to the top of substrate  602 , for example by pressing together the respective halves of RFID device  604 . In another exemplary embodiment RFID device  604  can couple to the top of substrate  602  by any of a variety of means, for example, a clip, clasp, spring, chemical coupling or the like. 
     If RFID device  604  is coupled to the top of substrate  602 , blade  606  can cut out, or otherwise remove a shaped section of substrate  602 . RFID device can be coupled to substrate  602  in such a manner that upper blade point  608  is located above the top edge of substrate  602  and the conductive material within. The shaped section cut out of substrate  602  can form the antenna for RFID tag  600 . 
     RFID device  604  can house strap  612  and RFID chip  614 . Strap  612  can be oriented in such a manner that if RFID device  604  is clipped to the top of substrate  602 , strap  612  can couple with the antenna formed by the shaped section cut out of substrate  602 . RFID Chip  614  and strap  612  can couple with the formed antenna and can make RFID tag  600  operable. 
     In one exemplary embodiment RFID tag  600  can be a sales tag that can be affixed to an item, for instance an article of clothing. RFID can be affixed to an item, for example by a pin retained inside RFID device  604 , other securing or affixing devices include adhesives, mechanical fasteners, hook and loop fasteners, Swiftach® fasteners (available from Avery Dennison Corporation, Pasadena, Calif.) or other fastening devices known in the industry. 
     In another exemplary embodiment, RFID tag  600  can be removed from an item using any suitable device, for example a magnet or pattern of magnets, clamp tools and the like. Furthermore RFID device  604  can be recovered from the waste chain after an initial use, and can be recycled and reused. 
     In another exemplary embodiment, RFID tag  600  can also serve additional functions, for example as an electronic article surveillance (EAS) device, for loss prevention, theft protection or any other embodiments where RFID is required. 
     It will thus be seen according to the present invention a highly advantageous RFID device and method of using an RFID intermediate has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, and that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. 
     Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.