Abstract:
An RFID tag comprising a label material including a printing surface and an adhesion surface opposite the printing surface, the adhesion surface including an adhesive operative to mount at least one RFID inlay to the label material, the label material also including deformation indicia for a user to deform the label material to perpendicularly space the RFID inlay from the printing surface. The invention also includes a method of fabricating an RFID tag comprising: (a) printing onto a printing surface of a label material, where the printing surface is defined in party by an X-Y plane; (b) encoding an RFID chip concurrent with the act of printing; (c) removing at least a portion of a backing material from an adhesive layer of the label material to expose an adhesive applied to the label material; and (d) deforming a portion of the label material onto itself, thereby trapping the RFID inlay between the label material so that the RFID is spaced apart in a Z-axis direction from the X-Y plane of the printing surface between 3 to 10 millimeters.

Description:
INTRODUCTION TO THE INVENTION 
       [0001]    A challenge to widespread application of radio frequency identification (“RFID”) tags, radio frequency electronic article surveillance (“RF-EAS”) tags, and other electronic labels (collectively “smart labels”) is providing adequate spacing between the item-to-be-tracked and the radio frequency inlay of the smart label. This is particularly the case where the tag is to be applied to metals or items containing water-based liquids. 
         [0002]    Metal objects reflect radio waves, while liquids generally absorb radio waves. In an instance where a smart label is placed too close to a metallic item or liquid, the smart label reader (i.e., scanner) detects signals that create background noise signals that hamper proper identification of the intended signals emitted from the smart label. In other words, liquids absorb (do not reflect) the RF signals, whereas metals reflect the RF signals in directions away from the RF scanner. 
         [0003]    The present invention overcomes some of these prior art deficiencies by positioning the inlay/transponder a distance away from the items allowing the reader to receive smart label signals. The invention also utilizes a high speed fabrication process to form the smart labels. A more thorough understanding of the invention will be apparent upon reference to the Detailed Disclosure of the Invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is an elevated perspective view of a first exemplary embodiment of a smart label in accordance with the present invention; 
           [0005]      FIG. 2  is a plan view of an exemplary label material for use with the exemplary embodiment  FIG. 1 ; 
           [0006]      FIG. 3  is a plan view of the exemplary embodiment of  FIG. 1 , shown in the upright position; 
           [0007]      FIG. 4  is a plan view of the exemplary embodiment of  FIG. 1 , shown in a compressed position; 
           [0008]      FIG. 5  is an overhead view of the exemplary label material of  FIG. 2 , prior to fabrication of the embodiment of  FIGS. 1 and 3 ; 
           [0009]      FIG. 6  is a plan view of an exemplary folding step in accordance with fabricating the smart tag of  FIGS. 1 and 3 ; 
           [0010]      FIG. 7  is a plan view of an exemplary folding step in accordance with fabricating the smart tag of  FIGS. 1 and 3 ; 
           [0011]      FIG. 8  is a plan view of an exemplary folding step in accordance with fabricating the smart tag of  FIGS. 1 and 3 ; 
           [0012]      FIG. 9  is an elevated perspective view of a second exemplary smart label in accordance with the present invention; 
           [0013]      FIG. 10  is an overhead view of an exemplary label material for use with the exemplary embodiment  FIG. 9 ; 
           [0014]      FIG. 11  is a bottom view of an exemplary label material, without the backer/liner, for use with the exemplary embodiment  FIG. 9 ; and 
           [0015]      FIG. 12  is a plan view of the second exemplary smart label. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The exemplary embodiments of the present invention are described and illustrated below to encompass methods, and items for carrying out such methods, for use in the manufacture, production, and application of smart labels. Of course, it will be apparent to those of ordinary skill in the art that the preferred embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below include optional steps or sub-methods that one of ordinary skill will recognize as not being a requisite to fall within the scope of the present invention. 
         [0017]    Referencing  FIGS. 1-3 , a first exemplary smart tag  10  includes a label material  12  and an inlay  14 . The label material  12  may be any paper, film, fabric, or laminate, including those suitable as a pressure sensitive label stock, while the inlay  14  includes a radio frequency identification (RFID) component. The smart tag  10  includes a top surface  16  and an underneath surface  18  opposite the top surface. In this first exemplary embodiment, the underneath surface  18  is coated with an adhesive  20  in order to mount the smart tag  10  to the eventual article  50  in question. However, it is to be understood that the adhesive  20  need not be applied to the entire back surface  18 . 
         [0018]    This first exemplary smart tag  10  includes a T-shaped projection  22  operative to space the inlay  14  from the top surface  16  adjacent to the eventual article  50 . As will be discussed in more detail later, this spacing is operative to allow the RFID reader to more accurately read the information disseminated by the RFID component of the inlay  14 . In this first exemplary embodiment  10 , the projection  22  is fabricated from the label material  12  to include a repositionable spacer  24  and an RFID envelope  26 . The spacer (in this first exemplary embodiment in the shape of a wall)  24  extends continuously from the top surface  16  of the label material  12 , while the opposite end of the wall  24  continuously extends from the RFID envelope  26 . In this manner, the RFID envelope  26  surrounds the inlay  14  using the adhesive  20  on the back surface  16  of the label material  12 . For purposes of simplicity in the drawings, the adhesive  20  is not shown in  FIG. 3 . 
         [0019]    Referring to  FIGS. 3 and 4 , one of the novel features of the first exemplary smart tag  10  is the flexibility of the projection  22  to be repositioned from an upstanding position (see  FIG. 3 ) to a fully retracted position (see  FIG. 4 , showing a retracted, but not fully retracted position). For example, when the projection  22  is in its upstanding position, the wall  24  is vertically oriented in a generally perpendicular position with respect to the top surface  16  of the tag  10  adjacent to the eventual object  50 , while the RFID envelope  26  is horizontally oriented in a generally parallel position with respect to the top surface  16 . Conversely, when the projection  22  is in its fully retracted position, the wall  24  and RFID envelope  26  are generally horizontally oriented and in parallel with respect to the top surface  16 . This flexibility allows the exemplary smart tags  10  to be stored in the fully retracted position in a stacked manner, where the profile of each tag is substantially flush. At the point in time when the tag  10  is to be mounted to an article, the projection  22  may be repositioned to its upstanding position for end use. Conversely, the tag  10  may be folded just prior to application to the end object  50  so that the projection  22  is oriented in its upstanding position spaced apart from the top surface that will be adjacent to the eventual object  50 . 
         [0020]    Referencing  FIGS. 5-8 , fabrication of the first exemplary smart tag  10  includes utilization of the label material  12  having the adhesive  20  applied to the underneath surface  18 . While the label material  12  from a vendor may include an adhesive  20  applied to at least one surface, it is also within the scope of the invention to apply adhesive  20  to a label material  12  not otherwise having the same or to apply a second layer of adhesive to label material already having a first adhesive layer. Those skilled in the art are familiar with the equipment and methods for applying an adhesive  20  to a label material  12 . In this exemplary embodiment, the underneath surface  18  includes an adhesive  20  layer across substantially the entire surface, while the top surface  16  does not. 
         [0021]    The label material  12  includes perforations  30  in a predetermined pattern to facilitate the folding and/or forming of the projection  22 . In this exemplary embodiment, the label material  12  includes six repeating perforations  32 ,  34 ,  36 ,  38 ,  40 ,  42  that extend substantially the entire width of the label material to form five zones  43 ,  44 ,  45 ,  46 ,  47  therebetween. These perforations  32 ,  34 ,  36 ,  38 ,  40 ,  42  may be formed in the label material  12  prior to, or subsequent to, adhesive application. As will be discussed in more detail hereafter, the perforations  32 ,  34 ,  36 ,  38 ,  40 ,  42  also facilitate enveloping the inlay  14 . 
         [0022]    Referring to FIGS.  3  and  6 - 8 , assembly of the first exemplary smart tag  10  includes orienting the label material  12  to expose the adhesive  20  on the underneath surface  18 . This may be accomplished by inverting the label material  12  so that the underneath surface  18  faces upward, but need not be as the exemplary process may be carried out with the top surface  16  facing upward. Referencing  FIGS. 6 and 7 , the tag  10  is folded along the intermediate perforations  32 ,  38  to pride a generally block U-shape, with the inlay  14  facing upward. Referencing  FIG. 8 , the label material  12  and adhesive  20  are formed around the inlay  14  so that the inlay  14  is circumferentially enveloped by the adhesive  20  and label material  12 . Concurrent with enveloping the inlay, the tag  10  is folded along the two innermost perforations  34 ,  36  so that the label material is substantially flat. Thereafter, the exposed ends of the label material  52 ,  54  are pushed inward so that the tag  10  folds along the two outermost perforations  40 ,  42  so that the adhesive portions between folds  38 ,  40  and  32 ,  42  contact one another to form the wall  24 . Following this process, the three innermost zones  43 ,  44 ,  45  envelope the inlay  14 , while the two outermost zones  46 ,  47  bond to one another to form the wall  24 . If the above process is carried out well prior to end use, a tear away backing (not shown) may be applied to the tag  10  to protect against inadvertent adhesion until the tag is ready for end use. As would be apparent to one of ordinary skill in the art, it is not necessary that the entire underneath surface  18  of the label material  12  be coated with the adhesive  20  in order for an exemplary smart tag  10  to be adhered to the product, container or other item  50  that is to be tracked. 
         [0023]    Dimensions for the exemplary smart tag  10  may depend on the end application and types of RFID components utilized. However, for purpose of explanation only, the wall  24  has a height of 1-10 millimeters, and a thickness of approximately 0.001-0.030 millimeters, with a length determined in part by the dimensions of the label material  12 . Likewise, the RFID envelope  26  has a height of approximately 0.003-0.090 millimeters, and a width of approximately 2-20 millimeters, with a length determined in part by the lengths of the label material  12  and the inlay  14  (which in exemplary form is approximately 100 millimeters). In this exemplary embodiment, the label material  12  has a thickness of approximately 0.004 millimeters. 
         [0024]    Referring to  FIG. 3 , the RFID inlay  14  is spaced from the top surface  16  of the tag  10  to reduce interference. This spacing is referred to as the spacing height  60 . Typically, the spacing height  60  is between 1-10 millimeters, but it may depend on the angle between the top surface  16  and the wall  24 , as well as the angle between the wall  24  and RFID envelope  26 . Where the angle between the top surface  16  and the wall  24 , as well as the angle between the wall  24  and the RFID envelope  26 , is at a right angle (i.e., perpendicular), the spacing height  60  of the substrate  26  is approximately equal to the height of the wall  22 . In this exemplary embodiment, the length of the RFID envelope  26  is greater than twice the height of the wall  24 . Having the length of the RFID envelope  26  greater than twice the height of the wall  24  is operative to inhibit the RFID inlay  14  from being oriented perpendicular with respect to the top surface  16 . 
         [0025]    Referencing  FIGS. 9-12 , a second exemplary smart tag  110  is fabricated from a label material  112  and an RFID inlay  114 . In this exemplary embodiment, the label material  112  includes a printing surface  116  and an opposite back surface  118  having an adhesive  119  applied thereto. The label material  112  is folded in accordance with a predefined pattern that includes five perforations  120 ,  122 ,  124 ,  126 ,  128  corresponding to four zones  130 ,  132 ,  134 ,  136  between the perforations. The folding operation is operative to form a wall  133  coupled to an encapsulated RFID portion  140 . 
         [0026]    Assembly of the second exemplary smart tag  110  includes orienting the label material  112  to expose the adhesive backed surface  118 . This may be accomplished by inverting the label material  112  so that the underneath surface  118  faces upward, but need not be as the exemplary process may be carried out with the printing surface  116  facing upward. A bottom surface  138  of the RFID inlay  114  is positioned opposite the adhesive backed surface  118  and lengthwise aligned along one of the two the inner perforations  124 ,  126  so that the longitudinal portion of the inlay is generally aligned with the widthwise dimension of the label material  112 . Pressure is applied to the bottom surface  138  of the RFID inlay  114  to mount the top surface to the adhesive backed surface  118  of the label material  112 . A folding process is then carried out to fold over the remainder of the second zone  132  around the bottom surface  138  of the inlay  114 , thereby encapsulating the inlay and forming the encapsulated RFID portion  140 . Ideally, this folding will result in the two intermediate perforations  122 ,  126  being adjacent one another and allowing the encapsulated RFID portion  140  to tilt with respect to the wall  133 . At substantially the same time, the vertical wall  133  is formed by pressing the adhesive exposed surfaces of the first and fourth zones  130 ,  136  together, with the two outermost perforations  120 ,  128  being adjacent one another in order to allow the wall  134  to tilt with respect to the printing surface  116  of the smart tag  110 . If the above process is carried out well prior to end use of the tag  110 , a tear away backing  150  may be applied to the tag  110  to protect against inadvertent adhesion until the tag is ready for end use. As would be apparent to one of ordinary skill in the art, it is not necessary that the entire back surface  118  of the label material  112  be coated with the adhesive in order for an exemplary smart tag  110  to be adhered to the product, container or other item that is to be tracked. 
         [0027]    Dimensions for the exemplary smart tag  110  may depend on the end application and types of RFID components utilized. However, for purpose of explanation only, the wall  133  has a height of 1-10 millimeters, and a thickness of approximately 0.001-0.030 millimeters, with a length determined in part by the dimensions of the label material  112 . Likewise, the encapsulated RFID portion  140  has a height of approximately 0.003-0.090 millimeters, and a width of approximately 2-20 millimeters, with a length determined in part by the lengths of the label material  112  and the RFID inlay  114 . In this exemplary embodiment, the label material  112  has a thickness of approximately 0.004 millimeters. 
         [0028]    Referring to  FIG. 12 , the RFID inlay  114  is spaced from the printed surface  116  of the tag  110  to reduce interference. This spacing is referred to as the spacing height  142 . Typically, the spacing height  142  is between 1-10 millimeters, but it may depend on the angle between the printed surface  116  and the wall  133 , as well as the angle between the wall  133  and the encapsulated RFID portion  140 . Where the angle between the printed surface  116  and the wall  133 , as well as the angle between the wall  133  and the encapsulated RFID portion  140 , is at a right angle (i.e., perpendicular), the spacing height  142  of the encapsulated RFID portion  140  is approximately equal to the height of the wall  133 . In this exemplary embodiment, the length of the encapsulated RFID portion  140  is greater than the height of the wall  133  to inhibit the RFID inlay  114  from being oriented perpendicularly with respect to the printed surface  116 . 
         [0029]    Exemplary RFID inlays as described in the foregoing embodiments are commercially available from the following vendors: (1) Alien Technologies ( ); (2) Avery Dennison RFID (www.rfid.averydennison.com); and, (3) UPM Raflatac (www.upmraflatac.com). Exemplary label material for use in the foregoing embodiments is available from UPM Raflatac ( ). 
         [0030]    Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.