Abstract:
Methods and apparatus for testing the health of each of a plurality of RFID transponders is provided. The apparatus includes an antenna support assembly including an antenna support body and an antenna coupled to a surface of the antenna support body, the antenna including at least a receiver portion and a connection portion. The apparatus also includes a holder coupled to the antenna support body configured to retain the antenna support proximate a path of a plurality of transponders.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to wireless communication systems and, more particularly, to manufacturing 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]     RFID transponders for articles in a global supply chain are mass produced in rolls of many hundreds or thousands of tags. Verifying the proper operation of such a large quantity of tags is laborious and time consuming. Verification of operation after the tag is fully assembled with an antenna, for example, in a completed strap, wastes the material of the strap and antenna and the manufacturing steps required to complete the strap if the transponder is found to be defective during testing of the completed strap. Accordingly, is it not desirable to attach an antenna and complete assembly of the transponder if it is defective. However, testing a large quantity of transponders before the strap is completed is difficult because communicating with the transponder uses the antenna.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0006]     In one embodiment, an apparatus for testing the health of each of a plurality of RFID transponders includes an antenna support body and an antenna coupled to a surface of the antenna support body, the antenna including at least a receiver portion and a connection portion. The apparatus also includes a holder coupled to the antenna support body configured to retain the antenna support body proximate a path of a plurality of transponders.  
         [0007]     In another embodiment, a packaging handling system for at least one of manufacturing and assembling radio frequency identification enabled packaging material includes a supply of packaging material, a supply of RFID straps including a web wherein the RFID straps are adhesively coupled to the web, the RFID straps are configured to be removed from the web and adhesively coupled to the supply of packaging material, a testing apparatus including, an antenna support assembly including an antenna coupled to a surface of the antenna support assembly, the antenna including at least a receiver portion and a connection portion and a holder coupled to the antenna support assembly configured to retain the antenna support assembly in a substantially fixed position proximate a web path of a plurality of transponders coupled to a web.  
         [0008]     In yet another embodiment, a method of testing an RFID enabled component proximate a plurality of RFID enabled components includes providing a plurality of RFID enabled components, temporarily coupling an antenna to at least one of the plurality of RFID enabled components, and determining the health of the at least one of the plurality of RFID enabled components using the temporary antenna. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a schematic diagram of an exemplary testing system for an RFID-enabled component;  
         [0010]      FIG. 2  is a schematic diagram of the web of straps proximate the antenna shown in  FIG. 1 ;  
         [0011]      FIG. 3  is a schematic diagram of an exemplary antenna support assembly that includes a convexly curved surface;  
         [0012]      FIG. 4  is a schematic diagram of an exemplary antenna support assembly that includes contact pads that extend circumferentially about a substantially cylindrical surface of the antenna support assembly; and  
         [0013]      FIG. 5  is a schematic diagram of another exemplary antenna support assembly  116  that includes a continuous belt having a plurality of antennas spaced about a radially outer surface. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     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.  
         [0015]      FIG. 1  is a schematic diagram of an exemplary testing system  100  for an RFID-enabled component, such as a strap  102 . In the exemplary embodiment, strap  102  includes an electronic circuit chip  104  and a contact pad  106  and  108  coupled to contact bumps (not shown) extending from a surface (not shown) of chip  104 . Strap  102  is adhesively coupled to a strap substrate  110 . In one embodiment of the invention, strap  102  includes a heat activated anisotropic conductive adhesive coupled to at least one surface of strap  102 . A web  112  of flexible material supports straps  102 . Typically, web  112  is rolled onto a spool such that a plurality of straps  102  is supplied in a roll that is couplable to a dispensing machine using the spool. An antenna  114  is coupled to an antenna support assembly  116 . Antenna  114  is printed onto a surface  118  antenna support assembly  116  using a conductive ink, for example, an ink containing at least one of copper, aluminum, silver, and organic conducting polymers. Alternatively, a conductive foil antenna, for example, an antenna containing at least one of aluminum, silver and copper foil is coupled to antenna support assembly  116  using, for example, an adhesive. Antenna  114  on antenna support assembly  116  is pressed into substantial contact with contact pads  106  and  108  such that electrical contact is made between contact pads  106  and  108  and antenna  114 . Alternatively, antenna  114  on antenna support assembly  116  is pressed proximate to contact pads  106  and  108  such that contact pads  106  and  108  and antenna  114  are capacitively coupled. To facilitate contact or proximity of contact pads  106  and  108  and antenna  114 , a roller  120  is used to apply a force against web  112  of hold contact pads  106  and  108  and antenna  114  in contact or relatively close proximity. A reader antenna  122  is positioned proximate antenna  114  and antenna  122  is coupled to an RFID reader  124 .  
         [0016]     During operation, web  112  carries straps  102  proximate antenna  114 . In one embodiment, web  112  slides across surface  118  such that contact pads  106  and  108  of each strap  102  sequentially pass proximate antenna  114 . In another embodiment, slidable engagement between web  112  and antenna  114  is facilitated using roller  120 . In still another embodiment, a pad is used to intermittent push web  112  against antenna  114  when strap  102  is positioned proximate antenna  114 . While contact pads  106  and  108  and antenna  114  are communicatively coupled by their close proximity and/or electrical contact, reader  124  generates RF signals which, are transmitted to electronic circuit chip  104  through reader antenna  122  and antenna  114 . If reader  124  receives a predetermined response from chip  104  the associated strap  102  is determined to be functional. If reader  124  does not receive a response from chip  104 , the strap is determined to be non-functional and is marked or otherwise indicated that strap  102  is non-functional and a next strap  102  is indexed into position proximate antenna  114  and the test repeated. Because of the relatively short amount of time required to perform the test, web  112  may be moving continuously at a relatively high rate of speed during the test. Alternatively, to facilitate an optimal read range, the accurate placement of strap  102  directly over the antenna contact pads is facilitated using a mechanical or optical indexing system  200 . For chips  104  that operate in the UHF range, reader antenna  122  is positioned relatively close to strap  102  and antenna  114  for a near-field reading and relatively further away for a far-field reading. By temporarily coupling antenna  114  to a single strap  102  or a predetermined number of straps  102 , the straps are effectively singulated such that it is not necessary to provide additional shielding of the other straps. A thin coating may be applied to the antenna to facilitate minimizing wear.  
         [0017]      FIG. 2  is a schematic diagram of the web  112  of straps  102  proximate antenna  114 . In the exemplary embodiment, roller  120  applies a force to web  112  that facilitates holding contact pads  106  and  108  and antenna  114  in contact with respect to each other or in close proximity with respect to each other. In the exemplary embodiment, roller  120  is illustrated as a cylindrical body configured to roll while applying a force of web  112 . In an alternative embodiment, roller  120  is a pad that slidably engages web  112  to apply a force to retain web  112  proximate antenna  114 .  
         [0018]      FIG. 3  is a schematic diagram of an exemplary antenna support assembly  116  that includes a convexly curved surface  118 .  FIG. 4  is a schematic diagram of an exemplary antenna support assembly  116  that includes contact pads  402  that extend circumferentially about a substantially cylindrical surface of antenna support assembly  116 .  FIG. 5  is a schematic diagram of another exemplary antenna support assembly  116  that includes a continuous belt  502  having a plurality of antennas  114  spaced about a radially outer surface  504 .  
         [0019]     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.  
         [0020]     The above-described embodiments of an in-line RFID transponder testing system provide a cost-effective and reliable means for testing of RF identification enabled transponders at a speed compatible with mass production of RFID-enabled products. The system provides a method of determining the health of a chip on a strap pre-sorting and/or marking defective straps such they may be discarded before being assembled into packaging material, tags, labels, or other RFID enabled product and so that a credit can be obtained from the supplier. The testing is non-contact in one embodiment or carried out at low contact pressure in another embodiment. As a result, the described methods and systems facilitate in-line RFID transponder testing in a cost-effective and reliable manner.  
         [0021]     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.  
         [0022]     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.