Abstract:
Methods and apparatus for manufacturing corrugated paperboard are provided. The apparatus includes a linerboard feed device configured to supply a quantity of linerboard including a plurality of antennae coupled to a first planar surface of the linerboard, an optical sensor configured to locate a connection area of the plurality of antennae, and an attach mechanism configured to couple a radio frequency identification circuit to the connection area.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to wireless communication systems and, more particularly, to container structures that incorporate radio frequency identification (RFID) components.  
         [0002]     At least some known RFID systems include a transponder, an antenna, and a transceiver with a decoder, or a reader. The transponder typically includes a radio frequency integrated circuit, and an antenna positioned on a substrate, such as an inlet or tag. The antenna receives RF energy from the reader wirelessly and transmits the data encoded in the received RF energy to the radio frequency integrated circuit.  
         [0003]     RF transponder “readers” utilize an antenna as well as a transceiver and decoder. When a transponder passes through an electromagnetic zone of a reader, the transponder is activated by the signal from the antenna. The reader decodes the data on the transponder and this decoded information is forwarded to a host computer for processing. Readers or interrogators can be fixed, mobile or handheld devices, depending on the particular application.  
         [0004]     Several different types of transponders are utilized in RFID systems, including passive, semi-passive, and active transponders. Each type of transponder may be read only or read/write capable. Passive transponders obtain operating power from the radio frequency signal of the reader that interrogates the transponder. Semi-passive and active transponders are powered by a battery, which generally results in a greater read range. At least some known semi-passive transponders operate on a timer and periodically transmit information to the reader. Transponders are also activated when they are read or interrogated by a reader. Active transponders are capable of initiating communication with a reader, whereas passive and semi-passive transponders are activated only when they are read by another device first. When multiple transponders are located in a radio frequency field, each transponder may be read individually or multiple transponders may be read substantially simultaneously. Additionally, in various embodiments, one or more environmental sensors are coupled to the transponders to sense environmental conditions, such as temperature, pressure, humidity, vibration, and shock. The status of the environmental condition is then communicated to the reader.  
         [0005]     Transponders typically are attached to an article, such as a corrugated box or a folding carton, in the form of a smart label or tag that includes a radio frequency integrated circuit, an antenna, and a backing substrate, usually polyester or paper, together with a release layer. The assembled label is then attached to the article by means of a pressure-sensitive adhesive that is incorporated into the label. However, such a process is not cost-effective for the mass application of RFID transponders to a large quantity of articles in a global supply chain.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0006]     In one embodiment, an apparatus for manufacturing corrugated paperboard is provided. The apparatus includes a linerboard feed device configured to supply a quantity of linerboard including a plurality of antennae coupled to a first planar surface of the linerboard, an optical sensor configured to locate a connection area of the plurality of antennae, and an attach mechanism configured to couple a radio frequency identification circuit to the connection area.  
         [0007]     In another embodiment, a corrugate machine for manufacturing radio frequency identification enabled corrugated paperboard is provided. The machine includes a press configured to couple a plurality of antennae to a first planar surface of supply of linerboard, a corrugator configured to corrugate a quantity of corrugating material stock into a corrugated medium, a double facer configured to join the corrugated medium to the linerboard on a side of the linerboard opposite the first planar surface to form a corrugated structure, an optical sensor configured to locate a connection area of the plurality of antennae, and an attach mechanism configured to couple a radio frequency identification circuit to the connection area.  
         [0008]     In yet another embodiment, a method of forming a corrugated panel is provided. The method includes providing a plurality of antennae on a quantity of linerboard, the antennae printed using a conductive ink, optically locating an antenna connection area, and coupling a radio frequency identification circuit to the antenna connection area such that radio frequency energy received by the antenna is transmitted to the radio frequency identification circuit. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a schematic view of an exemplary printing press that may be used to print RFID antennae on linerboard;  
         [0010]      FIG. 2  is a schematic view of an exemplary RF enabled strap that may be used with the linerboard and antennae shown in  FIG. 1 ;  
         [0011]      FIG. 3  is a schematic view of an exemplary corrugate machine that may be used to apply radio frequency identification enabled straps to the linerboard shown in  FIG. 1 ; and  
         [0012]      FIG. 4  is a flowchart of an exemplary method  400  of forming a corrugated panel. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0013]     As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.  
         [0014]      FIG. 1  is a schematic view of an exemplary printing press  100  that may be used to print RFID antennae on linerboard. Press  100  may use any print process capable of performing the functions described herein. In the exemplary embodiment, press  100  receives a supply of linerboard  102  continuously from a web roll  104 . Linerboard  102  then passes between an impression cylinder  105  and a blanket cylinder  106  that includes a thick rubber sheet or blanket  108  that transfers ink from a plate cylinder  110  to linerboard  102 . In at least one type of printing, for example, in gravure printing, a similar rubber sheet covers impression cylinder  105 . Impression cylinder  105  is configured to press linerboard  102  against blanket  108  in an offset printing configuration or against a plate  112  in a gravure printing configuration. Plate cylinder  110  includes at least one plate  112  fixed to an outer peripheral surface thereof. In the exemplary embodiment, plate  112  includes an image of an antenna  114  formed by photo-mechanically transferring the image from a film (not shown).  
         [0015]     Press  100  includes a source of fountain solution  115  that, in the exemplary embodiment, includes a mixture of water and chemicals, the mixture dampens printing plate  112  to facilitate preventing ink from adhering to a non-image area on a surface of plate  112 . In the exemplary embodiment, one or more dampening rollers  116  are used to facilitate even distribution and a proper amount of fountain solution  115  along the surface of plate  112 . In addition, one or more ink rollers  118  are used to apply a supply of ink to plate  112 . A supply of over-print varnish  120  is applied to linerboard  102  after the transfer of the antenna image to linerboard  102  using a varnish roller  122  and a web transfer cylinder  124 . Antenna  114  includes one or more reception areas  126  and one or more connection areas  128 . A single reception area includes a predetermined pattern of conductive material extending between reception areas  126 . An embossing device  130  is used to create a depression in linerboard  102  at connection area  128 . Alternatively, an embossed depression is formed with the raw linerboard stock or is formed as part of the process of printing antenna  114 .  
         [0016]     In operation, fountain solution  115  is applied to plate  112  as plate cylinder  110  is rotating. Dampening rollers  116  maintain a predetermined pressure along a surface of plate  112  to spread fountain solution  115  to a predetermined location and depth along plate  112 . Ink rollers  118  apply a predetermined selectable quantity of ink to the printing image area of plate  112 . The ink image is then transferred to blanket  108  rotating with blanket cylinder  106 . The ink image is then transferred to linerboard  102 , which is being fed continuously through press  100  between impression cylinder  105  and blanket cylinder  106 . In the exemplary embodiment, antenna  114  is printed using a conductive ink, such as an ink that includes a metallic and/or conducting polymeric component. Antenna  114  is printed under graphics printed on linerboard  102 , over the graphics, or printed in conjunction with other print processes that print graphics on linerboard  102 . In the exemplary embodiment, heat is added to linerboard  102  at any point to dry and/or cure the ink. An over print varnish (OPV) is applied to antenna  114  such that connection area  128  remains uncovered. In an alternative embodiment, no OPV is used. Linerboard  102  is wound on a take-up roll (not shown) when a downstream process is not available to process the linerboard or when off-line printing is used to supply linerboard to a production facility in an off-line print application. In the exemplary embodiment, linerboard  102  is fed directly to another downstream machine in an in-line process.  
         [0017]      FIG. 2  is a schematic view of an exemplary RF enabled strap  200  that may be used with linerboard  102  and antenna  114  (shown in  FIG. 1 ). In the exemplary embodiment, strap  200  includes a substrate  202 , an electrically conductive pad  204  that is printed on substrate  202  using a conductive ink. A radio frequency identification circuit  206  is electrically coupled to pad  204  through one or more bumps  208  extending away from a surface  210  of radio frequency identification circuit  206 . Radio frequency identification circuit  206  is coupled to substrate  202  using an adhesive  212 , such as a conductive or anisotropic epoxy or other adhesive material. An adhesive  214  is applied to assembled strap  200  to facilitate coupling strap  200  to antenna  114 .  
         [0018]     In the exemplary embodiment, radio frequency identification circuit  206  is a passive circuit. In various alternative embodiments, radio frequency identification circuit  206  is a semi-passive or active circuit that includes a battery (not shown) or capacitive storage device coupled to radio frequency identification circuit  206 . A sensor (not shown) is electrically coupled to radio frequency identification circuit  206  for communicating environmental data proximate the sensor. The sensor is of micro-mechanical design such that the sensor is incorporated into radio frequency identification circuit  206  or is a separate device that is communicatively coupled to radio frequency identification circuit  206 . The sensor is used to read an environmental or other condition in the vicinity of the sensor, for example, but not limited to, vibration, shock, temperature, pressure, and humidity. In an alternative embodiment, a plurality of sensors is coupled to each radio frequency identification circuit  206 . In one embodiment, the sensor is configured to read and transmit a signal corresponding to the environmental conditions when signaled by an RF reader. In various alternative embodiments, the sensors include a battery which permits the sensor to read and record the environmental conditions and transmit the recorded data when requested or interrogated by an RF reader.  
         [0019]      FIG. 3  is a schematic view of an exemplary corrugate machine  300  that may be used to apply radio frequency identification enabled straps  200  to linerboard  102 . Corrugate machine  300  includes a supply of a first linerboard  302 , a supply of a second linerboard  304 , a supply of a corrugating material stock  306 , and a supply  308  of RF identification enabled straps  200 . In the exemplary embodiment, straps  200  include a second substrate or web  310  having an adhesive release layer (not shown) coupled to web  310  such that straps  200  are handled collectively on a roll or fan-fold form and removed individually from web  310  for application to linerboard  102 . Corrugate machine  300  includes a corrugator  312 , a single facer  314 , a double facer  316 , a strap attach device  318 , and a cutter  339 . A plurality of idler rollers  322  are positioned at predetermined locations along a path of linerboard  102  to provide a predetermined amount of tension on linerboard  102  to facilitate movement of linerboard  102  through corrugate machine  300 . The embossed depression is sized to house radio frequency identification circuit  206  at least partially within the depression. Applying straps  200  such that radio frequency identification circuit  206  is within a depression facilitates protecting radio frequency identification circuit  206  during fabrication and during subsequent packaging and shipping operations.  
         [0020]     During operation, corrugating material stock  306  is fed into corrugator  312 , which corrugates the corrugating material stock  306  into a corrugated medium  324  having a plurality of flutes  326 . The corrugator  312  is positioned downstream from the supply of corrugating material stock  306 . An adhesive  328  is applied to the flutes  326  of the corrugated medium  324  by an adhesive applicator  330  after the corrugating material stock  306  is corrugated. Linerboard  302  moves in proximity to a pre-heater  332  and corrugated medium  324  is then joined to linerboard  302  by single facer  314 . Second linerboard  304  is fed through a second pre-heater  334 , and is then joined to the corrugated medium  324  and first linerboard  302  at double facer  316 . Prior to entering the double facer  316 , adhesive  328  is applied to flutes  326  of the corrugated medium  324  by a second adhesive applicator  337 . Adhesive  328  joins second linerboard  304  to corrugated medium  324  in double facer  316  to form a corrugated structure  338 . Corrugated structure  338  is then fed into a dryer  336 , which dries adhesive  328  and facilitates curing antenna  114 , adhesive  214 , and/or adhesive  212 . Corrugated structure  338  is then cut by a cutter  339  to form a plurality of blanks  340 .  
         [0021]     The RF components are applied to corrugated structure  338  at a plurality of different positions. A strap attach device  318  is used to apply strap  200  to an outside surface of corrugated structure  338 . In the exemplary embodiment, strap attach device  318  is illustrated in a position downstream from double facer  316 . In various alternative embodiments, strap attach device  318  is positioned in other locations.  
         [0022]     In the exemplary embodiment, strap attach device  318  includes a registration mechanism  342  for locating antenna  114  such that strap attach device  318  applies each strap  200  to a predetermined location on connection area  128 . In the exemplary embodiment, registration mechanism  342  includes an optical device, for example an electric eye or video camera that detects each connection area  128  prior to connection area  128  passing strap attach device  318 .  
         [0023]      FIG. 4  is a flowchart of an exemplary method  400  of forming a corrugated panel, including RF enabled components, for supply chain packaging materials. Method  400  includes providing  402  a plurality of antennae on a quantity of linerboard, the antennae printed using a conductive ink. In the exemplary embodiment, a preprint printing press or other off-line printing press upstream of the corrugator is used. Ink used to print the antennae is electrically conductive, for example, ink that incorporates metals, such as copper, aluminum and/or silver. In an alternative embodiment, inks incorporating organic conducting polymers are used. The antenna is printed using a lithographic or flexographic press, but any suitable printing technology can be used, such as rotogravure, rotary screen printing, ink jet printing, and pad printing. One or more conductive layers are printed if a thicker antenna is desired. Alternatively, a non-conductive primer layer can be used prior to printing the conductive ink. In various alternative embodiments, non-conductive (dielectric) layers are interposed between the conductive layers. The conductive antenna could also be sprayed onto the substrate, using a mask to define the shape of the antenna. Additionally, in alternative embodiments, drop-on-demand inkjet technology or continuous inkjet technology are used to apply the conductive ink, or the antenna is transferred from a release substrate by pressure and/or by thermal transfer.  
         [0024]     In the exemplary embodiment, the linerboard is, for example, clay-coated high-holdout linerboard. In an alternative embodiment, regular linerboard is used. The quality of the printed antenna varies according to the linerboard or substrate used and the printing technology employed. Applying the conductive antenna on linerboard upstream from the corrugator facilitates obtaining a uniform print. After the linerboard has been combined with corrugating medium in the corrugator, it is more difficult to ensure a uniform ink laydown due to variations of absorbency due to a “washboarding” effect that occurs in the corrugator.  
         [0025]     In the exemplary embodiment, the antenna is applied by strap attach. In an alternative embodiment, direct chip attach is used and a heat resistant overprint varnish (OPV) is applied over the printed antenna. A windowing application of the OPV that leaves the connection area uncovered facilitates making a reliable electrical contact between the antenna and the radio frequency identification circuit. The OPV may, for example, protect the printed antenna from damage as it passes through the drying section of the corrugator, enable the conductive ink to “cure”, and protect the antenna from damage during the remaining converting and other operations expected to occur in the supply chain. At least some known inks require exposure to temperatures of at least 150° C. to enable the full conductive properties to be obtained. An antenna passing through a corrugator is exposed to temperatures of approximately 180-200° C. in the corrugator drying section. Additionally, the OPV may provide antistatic protection to the strap components using antistatic additives incorporated into the OPV composition. Alternatively, a film patch is used in place of the OPV. When existing process heat sources are unavailable and/or inadequate for curing the printing ink, or other curing methods are required, for example, ultraviolet (UV) or electron beam (EB), additional heat sources, and additional equipment are added to the printing press and or corrugate machine.  
         [0026]     The connection area of each antenna is optically located  404  using a sensor, for example, an electric eye or a video camera. A controller communicatively coupled to the optical sensor processes the image of the antenna as the linerboard passes proximate the optical sensor to detect features of the antenna that are characteristic to the connection area. The controller then indexes the strap attach device such that the strap or radio frequency identification circuit chip are coupled  406  to the antenna at a predetermined location with respect to the connection area. The strap or radio frequency identification circuit chip is coupled  406  to the antenna connection area such that radio frequency energy received by the antenna is transmitted to the radio frequency identification circuit.  
         [0027]     Although the embodiments described herein are discussed with respect to supply chain packaging material, it is understood that the RF-enabled component assembly and processing methodology described herein is not limited to supply chain packaging applications, but may be utilized in other non-packaging applications.  
         [0028]     It will be appreciated that the use of first and second or other similar nomenclature for denoting similar items is not intended to specify or imply any particular order unless otherwise stated.  
         [0029]     The above-described embodiments of an in-line RFID transponder assembly system provide a cost-effective and reliable means for mass production speed assembly of RF identification enabled packaging material. More specifically, preprinting RFID antennas to linerboard and applying RFID straps to the antennae during fabrication of corrugated structures permits high speed production of supply chain packaging with RFID components applied during fabrication. As a result, the described methods and systems facilitate in-line RFID transponder assembly in a cost-effective and reliable manner.  
         [0030]     Exemplary embodiments of in-line RFID transponder assembly methods and apparatus are described above in detail. The in-line RFID transponder assembly components illustrated are not limited to the specific embodiments described herein, but rather, components of each imaging system may be utilized independently and separately from other components described herein. For example, the in-line RFID transponder assembly components described above may also be used in combination with different in-line RFID transponder assembly components. A technical effect of the various embodiments of the systems and methods described herein include facilitating assembly of RF enabled packaging materials at production level speeds.  
         [0031]     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.