Printer with integrated RFID data collector

A RFID printer for printing and determining the quality of RFID record members having transponders is provided. The RFID printer may be used to print RFID record members utilizing a continuous moving web. In particular, a RFID printer includes an integrated RFID data collector such that identifying RFID transponder information may be recorded and associated with a barcode for inventory tracking purposes. An association file created by the RFID printer may be transferred to a manufacturer or retailer brand owner. The association file may be deleted from the RFID printer upon acknowledgment of receipt of the transmitted association file to the manufacturer or retail brand owner. The RFID printer provides methods for determining quality of RFID printed record members.

FIELD OF THE INVENTION

The invention relates to RFID printers. More particularly, the invention concerns the ability to operate a RFID printer with an integrated RFID data collector such that RFID transponders may be recorded and associated with barcodes for inventory tracking purposes.

BACKGROUND

RFID (Radio Frequency Identification) class0transponders have been embedded in record members to track inventory. The data contained in the transponder is typically read by a stationary RFID read module as the inventory with the RFID transponder is carried past the stationary read module on a conveyor belt or the like. RFID printers are now required to be capable of both printing a bar code on record members, such as labels, tags etc., and capable of reading from a RFID transponder contained in the record member. The bar code may represent information in the form of a SKU identifying an item such as a product or garment.

Using preprogrammed class0transponders, inventory may be tracked using a RFID scanner to determine if a product needs to be replenished. Products to be replenished may be determined manually by an operator after completion of a RFID scan. Currently, there exist many problems with RFID printers and systems. For example, current RFID printer systems use external RFID readers and personal computers to store files. These systems do not assure that files are safely communicated and stored with a Retail Brand Owner (“RBO”) for inventory tracking purposes. Current systems are not secure and are susceptible to lost or corrupted files. These systems generally store information internally in the memory of the particular RFID printer.

Moreover, additional problems exist with current RFID printer configurations. For instance, existing RFID printers momentarily stop so that a RFID transponder or inlay in a record may be read. However, stopping of a web to read a RFID transponder increases the amount of time for overall job completion and limits overall throughput of the RFID printer. In addition, a number of RFID transponders are damaged during the printing process as current designs of top and bottom feed rollers exert excessive pressures on the transponders as the transponders move along the web.

Additionally, current RFID printers do not provide a visual indication to alert users if a mismatch between the number of record members printed and the number of “good” RFID transponders tracked in the association file have been detected. Furthermore, current RFID printers do not allow users to verify reliability of individual record members containing transponders.

Therefore, there is a need in the art for an improvement to the printing and reading of RFID record members particularly for record members being printed in batch processes.

Further background information regarding thermal printers that print on both sides of a web may be found in co-owned U.S. Pat. No. 7,125,182, issued Oct. 24, 2006 which is incorporated in its entirety.

The following additional patent documents and other literature are made of record and may or may not be prior art: U.S. Pat. Nos. 4,408,906; 5,524,993; 5,833,377; 6,246,326; 7,180,627; 7,190,270; U.S. Publication No. 2001/0029857; U.S. Publication No. 2004/0100381; U.S. Publication No. 2005/0116034; U.S. Publication No. 2005/0274800; U.S. Publication No. 2005/0280537; U.S. Publication No. 2006/0104689; U.S. Publication No. 2006-0273170; U.S. Publication No. 2006-0221363; Abstract of Japan Publication No. 2003-140548; Abstract of Japan Publication No. 2004-110994; Abstract of Japan Publication No. 2005-107991; Abstract of Japan Publication No. 2005-186567; Abstract of Japan Publication No. 2006-000936; Abstract of Japan Publication No. 2007-213298; Abstract of Japan Publication No. 2006-004150; and Abstract of Japan Publication No. 2008-124356.

SUMMARY

In accordance with various aspects of the invention, the disadvantages of prior printers as discussed above have been overcome. One aspect of the present invention provides an RFID printer for printing and determining the quality of RFID record members having transponders. The RFID printer may be used to print RFID record members utilizing a continuous moving web. In particular, a RFID printer includes an integrated RFID data collector such that identifying RFID transponder information may be recorded and associated with a barcode for inventory tracking purposes. An association file may be created by the RFID printer and may be transferred to a manufacturer or RBO. The association file may be deleted from the RFID printer upon acknowledgment of receipt of the transmitted association file to the manufacturer or RBO. In an aspect of the invention, the RFID printer may provide various methods for determining a measure of quality of RFID printed record members.

In an aspect of the invention, a RFID printer is capable of reading and printing a record member while the web is continuously moving. While the web is continuously moving, both sides of the record member may be printed upon with information in barcode form. In an embodiment, the RFID printer may include a RFID reader, a communication interface, and an antenna configured to emit a RFID field. The antenna may also be coupled to and cooperate with the RFID reader to read at least one RFID transponder included in a record member. The antenna may be located upstream of a print head. The RFID printer may include a printing system and a processor operable to read and print on the RFID record member as the web continues in motion.

In an embodiment, the RFID printer may read a RFID transponder to collect an identification number of the RFID transponder. The RFID printer may link the identification number of the RFID transponder with a barcode. An association file may be created which includes a listing of identification numbers of RFID transponders and associated barcodes. The association file may be stored in the RFID printer's non-volatile memory and transmitted upon receipt of an instruction to transmit completed association files.

In another aspect of the invention, the RFID printer may count the number of printed record members printed by the printing system of the RFID printer. The RFID printer may further determine if the counted number of printed record numbers exceeds a stored total number of record numbers allowed to be printed before receipt of an instruction to transmit the association file. In an embodiment, if the counted number of printed records exceeds the stored total number of record numbers allowed to be printed, then printing may be stopped until receipt of an instruction to transmit an association file.

In an additional aspect of the invention, an under cut feed roller assembly may be used with various embodiments of the invention. The under cut feed roller assembly may include top and bottom feed rollers having matching grooves to reduce excess pressure on a transponder.

In yet another aspect of the invention, a RFID printer capable of printing on both sides of a record member and creating an association file linking transponders to barcodes may also comprise a knife assembly to produce a square cut when cutting printed RFID record members.

In a further aspect of the invention, a record member with a RFID transponder may be marked as unusable in an association file and when the record member reaches a print position the record member is printed with an overstrike pattern or cut into pieces preventing accidental use of the defective record member.

In an embodiment, a RFID system may include a RFID printer and a host computer. The RFID printer may include a barcode scanner, a RFID reader, an antenna configured to emit a RFID field and coupled to and cooperating with the RFID reader to read at least one RFID transponder included in a record member, a printing system having a print head and a drive mechanism, and a processor. The processor may be configured to create an association file. The association file may include a listing of identification numbers of RFID transponders and associated barcodes. The RFID system may further include a host computer in communication with the RFID printer. The host computer may receive the association file from the RFID printer upon request and retransmit the association file to a manufacturer or RBO for inventory tracking purposes. The host computer may receive an acknowledgement of receipt of the retransmitted association file. Upon receipt of the acknowledgment, the host computer may instruct the RFID printer to delete the transmitted association file upon receipt of the retransmitted association file.

In a further aspect of the invention, a measure of quality for a RFID transponder may be determined. In an embodiment, a RFID printer may receive an instruction to enter a reader mode to detect RFID transponders. The RFID printer may collect information from a transponder and transmit such information to determine status of the RFID transponder. The information received regarding the RFID transponder may be forwarded through a web server to verify the received RFID transponder information. A first indication may be received if the RFID transponder information is discovered and valid. In an alternative embodiment, a second indication may be transmitted if the RFID transponder information in not discovered or if the RFID transponder is invalid.

In another aspect of the invention, a measure of quality for a RFID transponder may be determined. In an embodiment, a RFID printer may read a RFID transponder included in a record member as the record member advances on a continuous web. The RFID printer may count the number of reads for the RFID transponder and evaluate the RFID transponder based on the number of counted reads. If the number of counted reads is greater than or equal to a predetermined number, the RFID transponder may be marked as acceptable. Alternatively, if the number of counted reads is less than the predetermined number, the RFID printer may be marked as unacceptable. In an aspect of the invention, the predetermined number may be three. In an embodiment, a record member having a transponder that is marked as unacceptable may be over struck or cut into pieces.

DETAILED DESCRIPTION

One aspect of the present invention provides an RFID printer for printing and determining the quality of RFID record members having transponders. The RFID printer may be used to print RFID record members utilizing a continuous moving web. In particular, a RFID printer includes an integrated RFID data collector such that identifying RFID transponder information may be recorded and associated with a barcode for inventory tracking purposes. An association file may be created by the RFID printer and may be transferred to a manufacturer or RBO. The association file may be deleted from the RFID printer upon acknowledgment of receipt of the transmitted association file to the manufacturer or RBO. In an aspect of the invention, the RFID printer may provide various methods for determining a measure of quality of RFID printed record members.

In an aspect of the invention, a barcode may be printed identifying the SKU of an item on a tag that contains an encapsulated class0preprogrammed RFID transponder. The RFID printing system needs to reliably read these preprogrammed RFID transponders and associate them with a SKU printed on the tag or record member. Next, a tag may be placed on a garment or other item of manufacture. The created association files may be provided to the RBO for supply chain management.

With reference initially toFIG. 1, there is shown a printer generally indicated at50. While the invention is illustrated in connection with a thermal printer using dot heating elements to create images such as bar codes, graphics, alpha numeric characters and the like, the invention is also useful with printers such as ink jet, laser, xerographic, impact, and other types of printers. In the following description, the terms transponder and inlay are interchangeable. In addition, more than one inlay or transponder may be included in a record member.

FIGS. 1-4illustrate a printer50for printing on a printable web W of record members RM in accordance with an aspect of the invention. The printer50may be a RFID printer. The web W is initially in the form of a wound supply roll R mounted on an unwind mechanism generally indicated at52. The web W is drawn through the printer50in a direction generally from left to right. As the web W is paid out of the web roll R, the web roll R rotates clockwise in the direction of arrow A. The unwind mechanism52applies a slight tensioning force to the web W by attempting to rotate the roll R counterclockwise, that is, in a direction opposite to the direction of the arrow A. However, the force exerted on the web W to feed the web W through the printer50overcomes the force exerted by the unwind mechanism to enable the web W to be fed through the printer50. By this arrangement the web W is always maintained under the desired tension.

In an aspect of the invention, RFID printer50includes a print head assembly having a print head53′ and a cooperable platen in the form of a platen roll54. The RFID printer50also includes another print head assembly55having a print head55′ and a cooperable platen in the form of a platen roll56. The print head assembly53and the platen roll54may be termed the “first” print head assembly and the “first” platen roll, respectively, because they are upstream of the print head assembly55and the platen roll56. Similarly, the print head assembly55and the platen roll56are downstream of the print head assembly53and the platen roll54and may be termed the “second” print head assembly and the “second” platen roll. The print head assemblies53and55may be identical.

The thermal print head53′ at a side of the print head assembly53cooperates with the platen roll54to print on the underside of the web W. The thermal print head55′ at a lower side of the print head assembly55cooperates with the platen roll56to print on the upper surface of the web W.

The platen roll54is a non-driven or idler roll, but the platen roll56is a driven roll. During operation of RFID printer50, the platen roll56feeds the web W from the roll R past a guide mechanism generally indicated at57to between the print head53′ and the platen roll54and to between the print head55′ and the platen roll56. From there the web W passes to an auxiliary feed mechanism which feeds the web W to a cutter or cutter mechanism59. The cutter59cuts the web W into predetermined length sheets, in particular labels or tags.

In an embodiment, RFID printer50is thermal transfer type printer, wherein ink ribbons I pass between the thermal print heads and the web W. A first ink ribbon system62is associated with the first print head assembly53and the platen roll54, and a second ink ribbon system63in associated with the print head assembly55and the platen roll56. The ink ribbon systems62and63may be identical. The systems62and63each have a supply spindle64and a take-up spindle65of similar construction. Each spindle64mounts a supply roll SR and each spindle65mounts a take-up roll TR. Each roll SR and TR is mounted on a core66, and each spindle64and65is driven by a mechanism. Each system62and63may be microprocessor controlled.

In various aspects of the invention, record members RM are included on supply roll R. In an embodiment, the record members RM can be comprised of, for example, a web of paper or fabric labels, tags, or forms.

With continued reference toFIG. 1, each of the record members RM may include a RFID transponder. A typical transponder includes an integrated circuit chip and an antenna.

In addition,FIG. 1also shows an antenna assembly102. The antenna assembly102may be located upstream of print head assemblies53and55. The antenna assembly102may be comprised of a seamless aluminum box104(FIG. 4) to keep a generated RFID field focused. In an embodiment, the antenna assembly102may be located at a RFID reader. The antenna assembly102may radiate energy in a narrow beam towards an adjacent RFID transponder T that is aligned with an antenna550(FIG. 5). The RFID antenna550may radiate energy in response to a RFID module or reader602in order to read an adjacent RFID transponder. The RFID reader602is responsive to a controller604to drive the antenna550to read information from the adjacent RFID transponder T.

In an embodiment, the controller604includes a microprocessor608and memory610. The memory610may include non-volatile memory for storing data and application programs for RFID printer50.

FIG. 5illustrates a control block diagram in accordance with an aspect of the invention. InFIG. 5, a printer may include a communication interface404. In an embodiment, the communication interface404may include a radio frequency transceiver and/or one or more communication ports such as a RS 232 port, a serial port, USB port, firewire port, an infrared port, a parallel port, etc. . . . The communication interface404may allow the printer50to communicate with a host device to receive data therefrom or to transmit transaction data thereto. The communication interface404may enable RFID printer50to communicate with a host computer in real time. Alternatively, RFID printer50may be operated off-line such that the data received from a host computer is stored in a look-up table or the like in a memory of the printer for later use. Similarly, data may be entered via one or more of the input devices stored in a memory of the printer and later transmitted with a batch of data records to a host computer via a communication port404.

In accordance with an embodiment of the invention, microprocessor608controls the operations of RFID printer50in accordance with an application program that is stored in memory. The microprocessor608may operate directly in accordance with the application program. Alternatively, the microprocessor608may operate indirectly in accordance with the application program as interpreted by an interpreter program stored in the memory.

FIG. 6is an elevational view of an under cut feed roller assembly600for RFID printer50in accordance with an aspect of the invention. InFIG. 6, an under cut feed roller assembly comprises a drive frame1which supports a high friction or a grit roller6and a molded idler roller7. The assembly may be designed such that the rollers6and7have grooves where transponders pass during the reading and printing process. The grooves may enable the RFID printer to reduce the amount of pressure placed on transponders moving along a web W. The under cut feed roller assembly further includes a set of ball bearings3and bearing supports2. The ball bearing3may be mounted using various screws4, nuts9, and pins10. The under cut feed roller assembly may be connected to a drive feed shaft5and may be adjusted for different webs by thumb screw knob8.

FIG. 7is an elevational view of a knife assembly for a RFID printer50in accordance with an aspect of the invention. InFIG. 7, a knife assembly700comprises a rotary knife706and a twenty inch knife spacer703. The knife assembly700may enable RFID printer50to produce a square cut without buildup of adhesive from different size record members. The knife assembly may further include a set of bearings705, upright supports (701and704) and a knurled cup point712. Further components of the knife assembly700may include a torsion spring713and various connection hardware including screws (707,708,714), rivet711, and nuts709.

FIGS. 8-10describe flow charts which illustrate instructions in the form of computer-readable flow diagrams that may be implemented in various aspects of the invention by RFID printer50. The instructions in the form of flow diagrams may be program instructions comprising a single program or may be divided into various program modules. The program instructions may be compiled into a processor-executable format and/or a format such that the instructions can be interpreted by an interpreter. In addition, the program modules may be combined or distributed in various computing environments.

FIG. 8illustrates a flow diagram for uploading an association file in accordance with an aspect of the invention. InFIG. 8at a step802, a RFID printer may be queried for any completed association files. A completed association file may represent a file from a completed batch print job. In an embodiment, the batch print job may represent a contract from a RBO electronically forwarded through an FTP site to a tag or label supplier. The contract may be received, parsed, and stored in a database for use in creating a print job.

In step804, a determination may be made regarding whether an association file is available for uploading. If an association file is available for uploading the process continues to step806. If an association file is not available for uploading the process recycles to step802.

Next, in step806the RFID printer50may transmit the association file to a host computer. The host computer may receive the association file and upload the association file to an available FTP server of a manufacturer or RBO. If the upload to the FTP server is successful the process continues to step812. If the uploading is unsuccessful, the host continues to attempt to upload the association file to the FTP server.

The process continues to step812in which the host computer may notify the RFID printer50that the association file stored on the RFID printer may be deleted. In step814, the RFID printer may delete the association file and the process continues to step802.

In an aspect of the invention, the RFID printer may only be allowed to read and collect a predetermined number of RFID identification numbers as the RFID transponders pass under the RFID antenna550in the RFID printer50. If the predetermined number is exceeded the RFID printer50may stop printing record members. For instance, the predetermined number of RFID identification numbers that may be collected before uploading to a FTP server may be approximately 20,000. Those skilled in the art will realize that the predetermined number of RFID identification numbers that may be collected before uploading to a FTP server may vary and change depending upon the requested print job.

FIG. 9illustrates a flow diagram showing printing functionality of a RFID printer in accordance with an aspect of the invention. InFIG. 9at step902, RFID printer50may be asked if it is available for a next print job. A determination may be made by RFID printer50at step904as to whether RFID printer50has collected the maximum allowed RFID identification numbers saved in RFID printer50and not uploaded to an FTP server. If the maximum allowed number has been reached the print job may be refused and the process recycles to step902. If the maximum number has not been reached then the process continues to step906where the print job is transmitted to RFID printer50.

Next in step908, RFID printer50may build the images to be printed. In step910, the RFID printer50may read and record the next preprogrammed RFID number. At this point, the RFID printer50may be queried for any completed association files as described inFIG. 8.

Next, in step912a determination may be made regarding whether the RFID transponder is a good transponder. A quality measure may be implemented on RFID transponder to determine if the RFID transponder is functional. Such a quality measure may be, for example, a number of reads in a known RF field to determine status of the RFID transponder. If the RFID transponder is bad then in step916, the record member including the bad transponder is cut in half and the process returns to step908.

Returning to step912, if the RFID transponder is good, then the record member having the RFID transponder may be printed upon. Next, the process may continue to step918where the printer barcode on the record member may be scanned. If the scanned barcode returns an unacceptable result, then the record member may be cut in half and the process continues to step908.

If the scanned bar code returns an acceptable result, then the process may continue to step920where the recorded RFID transponder information and the barcode information may be linked and stored in non volatile memory. The linked information may be stored in an association file.

Next, the process may continue to step924for a determination if more tags are remaining in the print job to be printed. If it is determined in step924that more tags are to be printed then the process returns to step908. If it is determined in step924that no more tags are to be printed then the process continues to step926to wait for the next print job.

In another aspect of the invention, RFID printer50may monitor the last four recorded transponder identifications codes and compare these recorded transponder identification codes to the next read transponder identification code. If a match occurs between the last four recorded transponder identification codes and the next read transponder identification code, then the tag having the later read transponder identification code is rejected and destroyed at the knife assembly. This may reduce any error due to reflection of the transponder identification code.

FIG. 10illustrates a flow diagram for determining a measure of quality for a RFID transponder contained within a record member in accordance with an aspect of the invention. InFIG. 10, RFID printer50may be placed into a web checker mode. Next, in step1004, a RFID transponder may be placed under the RFID printer antenna550to be read. The process may continue to step1006where a test result may be determined. The RFID printer may transmit information regarding the RFID transponder through a host computer and network so that information regarding the RFID transponder may be checked and verified.

In a first outcome step as illustrated in step1014, the RFID transponder may not be functional. For example, the RFID printer may not be able to read the RFID transponder.

In a second outcome, shown in step1016, information regarding the RFID transponder is not located in a RBO database. As the RBO does not have any information regarding the RFID transponder, RFID printer50may be instructed to cut the record member or tag into pieces so that it is not placed on a garment. A visual signal such as a red light may be displayed to indicate that the RFID transponder was not discovered at the RBO and that the RFID transponder should be destroyed.

In a third outcome shown in step1008, the RFID transponder may be located in the RBO database and information regarding a corresponding barcode for the RFID transponder may be returned to the RFID printer50. A visual signal such as a green light may be displayed to a user to indicate that the RFID transponder was discovered at the RBO. Next, in step1010a determination may be made as to whether the barcode stored in the RBO database matched the barcode printed on the record member. If the barcode printed on the record member matches the barcode listed in the RBO database, then the next RFID transponder may be placed under RFID printer antenna550to be read. If the barcode printed on the record member does not match the barcode, then information regarding the record member may be transmitted to a host computer for further analysis of the record member and RFID transponder.

The invention has been described in terms of exemplary embodiments. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.