Abstract:
A method for making a container including a radio frequency identification label is provide. In an embodiment the method includes placing a radio frequency identification (RFID) label into a mold; positioning the RFID label so that an outer portion of the label is substantially flush with the mold surface; and molding a container such that the outer portion of the RFID label is substantially flush with the outer surface of the side wall of the container. An article, which may be formed using the foregoing method, is also disclosed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of application Ser. No. 10/847,492, filed May 17, 2004, which claims priority to U.S. Provisional Patent Application Ser. No. 60/506,750, filed Sep. 30, 2003, the entire contents of which are herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Currently containers, such as hollow plastic containers, and the like are provided with bar codes to track inventory and to identify inventory and to identify products at point of sale. It would be highly desirable to provide a more efficient system for this purpose as well as for other purposes where-tracking and/or identification are desirable. 
     Radio frequency identification (RFID) may be effectively used for this purpose. It involves the use of a small computer or memory chip that may uniquely identify an item when read by a scanner. Thus, using RFID one may simply and conveniently, for example, locate and track items in stockrooms and in stores, minimize backroom storage of merchandise, accurately identify returned merchandise, allow customers to check out by simply scanning the carts, and facilitate identification, counting and location of items in a rapid manner. Moreover, RFID can provide numerous other advantages, such as monitoring product expiration dates and identifying when products need to be removed from shelves, tracking inventory, tracking temperature history, and warning when shoplifting occurs and counterfeiting of product. 
     Thus, RFID technology can be expected to replace the familiar product bar codes and indeed provide numerous advantages thereover, some of which are indicated hereinabove. These are small and unobtrusive and can be easily and readily tracked and monitored to provide simple and rapid identification and data for a variety of purposes. 
     However, it would be highly advantageous to inexpensively and permanently apply RFID to products such that the identification does not represent an aesthetically objectionable configuration and is tamper proof. Simply adhering the RFID by adhesive means or applying same to a label would clearly not be entirely satisfactory. 
     It is, therefore, a principal object of the present invention to provide an improved plastic article which has radio frequency identification (RFID) simply, conveniently and expeditiously applied thereto. 
     It is a further object of the present invention to provide an improved article as aforesaid with permanent application of RFID thereto and with the unobtrusive location of same on the article. 
     It is a still further object of the present invention to provide an improved article as aforesaid that enables the effective application of RFID to a wide variety of articles, such as consumer products, pallets and other articles where RFID would be advantageous. 
     It is an additional object of the present invention to provide an improved plastic article including RFID integrally applied thereto. 
     Further objects and advantages of the present invention will appear hereinbelow. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention the foregoing objects and advantages are readily obtained. 
     The present invention provides for an improved article having an integral RFID or transponder as a permanent part of the article. The article is desirably a plastic article, as a hollow container or a pallet, that is injection molded and/or blow molded with a small computer or memory chip applied thereto in the injection molding or blow molding process so that the chip is integrally and conveniently applied thereto in the molding process. The chip with connections for an antenna or possibly the antenna itself and possibly also a battery could be applied in this manner. If the RFID is applied to a container, one could apply same to a desired location, as for example, on the base where it would not be readily visible, or on a side wall where it would be covered by a label and yet would not be removed when the label is removed. 
     The present invention also contemplates permanently applying RFID to a plastic article so that the RFID becomes an integral and permanent part of the article, as by inserting the RFID in the mold when the plastic article is injection molded and/or blow molded and molding the RFID to a desired location on the article. The RFID may if desired be applied in the molding process so that it is flush with the outside surface of the article. 
     Further features and advantages of the present invention will appear hereinbelow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be more readily understandable from a consideration of the following illustrative drawings, wherein: 
         FIG. 1  is a side view showing a preform positioned in a blow mold for forming a blow molded container; 
         FIGS. 2-3  are identification labels including a memory chip and antenna and connections therebetween; 
         FIG. 4  shows a hollow plastic article with identification label connected thereto and an adjacent reader; and 
         FIGS. 5-6  show alternate embodiments of hollow plastic articles with identification labels connected thereto. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     In accordance with the present invention one could form the chip as part of a product, as a container, during the injection molding or blow molding operation by placing the chip in the mold and forming the article with the chip integrally connected thereto in the molding process. The chip, with also possibly the antenna and also possibly a battery, could be applied on various places on the article as desired, as on the base of a container or on a side wall where it would be covered by a label and therefore not be visible. The chip could also if desired be placed on the neck of a container. If the frequency is difficult to read through the liquid contents of a container, application on the neck can obviate this difficulty. The chip, antenna and possibly a battery would become a permanent and integral part of the article in the molding process. The chip and antenna would desirably be mounted on a substrate as a plastic film or other desirable substrate, and integrally applied in this manner, with also a battery, if desired. Alternatively, the chip alone could be applied and the antenna printed post mold. Desirably, one can use a conductive material as at least a part of the application material or substrate, such as a silver or copper base ink. 
     It may be helpful to apply the chip with or without antenna by means of a magnet. A magnet would be placed in the mold to assist in registering the chip and antenna with or without battery in a desired location in the mold. 
     As a further alternative, chips with or without antennae could be delivered into the mold with air delivery and held in a desired location by a suitably positioned magnet. A recess area in the mold may be used to accommodate the chip and antenna. One may also use vacuum to position and hold the chip in place. The resultant chip and antenna would then be flush with the final article as the article is molded. Still further, the chips could be fed into the mold using a web with the chips, with or without antenna and battery, placed in register on the web and with indexing the web to the mold. 
     Labels could be applied over the integral chip and antenna. Label graphics could be integrated with the chip so that they alter over time activated by the chip, as for example when a product is approaching its expiration time, or has exceeded temperature limits, or for a special sales promotion, or for a price change. 
     Referring to the drawings,  FIG. 1  is a side view showing the preparation of blow molded container  10  (shown in phantom) having a radio frequency identification (RFID) label  12  integrally connected to the side wall  14  of the container. In accordance with the embodiment of  FIG. 1 , a straight, cylindrical warm plastic preform or parison  16  is positioned in blow mold  18 . Parison  16  has a closed base  20 , a straight body portion  22  extending upwardly therefrom, a straight neck portion  24  extending upwardly from the body portion, and an open mouth  26 . If desired, the parison has a threaded neck portion  28  and an outwardly extending flange  30  which aids in seating the parison  16  in the blow mold  18 . The blow mold  18  is closed on the parison firmly seating the parison in the blow mold. The RFID label  12  is held in the blow mold by holder  32  for integral connection with the side wall of the blow molded container  10  when the parison is expanded into conformity with the blow mold to form the blow molded container. Preferably, the RFID label is embedded in the container sidewall so as to be flush with the container sidewall. 
     Stretch rod  34  is positioned within the preform  16  and blow nozzle  36  is placed above the preform engaging open mouth  26 . If desired, the blow nozzle  36  may include downwardly extending flange  38  which is moved into engagement with the outside of neck portion  24 . In accordance with conventional procedure, stretch rod  34  is preferably fully extended in the clamped; warm preform to extend the preform to the base of the blow mold and to provide an extended preform. High pressure air is then introduced into the extended preform from blow nozzle  36  from a high pressure air source (not shown) to expand or stretch the extended, warm preform into conformity with the cavity  40  of blow mold  18  and with RFID label  12  integrally connected to the sidewall  14  of the blow molded container  10  as discussed above. Holder  32  releases RFID label  12  after the blow molding process. The result is a blow molded container  10 , desirably biaxially oriented, with RFID label  12  firmly connected to the sidewall surface of container  10 , and preferably embedded in the sidewall so as to be flush with the outside surface of the article. 
       FIGS. 2 and 3  show representative RFID labels.  FIG. 2  shows square label  50  with computer or memory chip  52  surrounded by circumferential antenna  54  on substrate  56 , as a plastic film. The chip is connected to capacitor  58  and to antenna  54  via first antenna connection  60  and second antenna connection  62 .  FIG. 3  is similar to  FIG. 2 , with a rectangular, elongated RFID label  150  having computer or memory chip  152  surrounded by an enlarged circumferential antenna  154  on an enlarged substrate  156 . Chip  150  is connected to capacitor  158  and to antenna  154  via first and second antenna connections  160 ,  162 , similar to  FIG. 2 . 
       FIG. 4  shows an alternate hollow plastic article  70  which is a blow molded container having an RFID label  72  on container sidewall  74  so that a product label can cover same. Reader  76  is disposed adjacent container  70  so that the electrical signals or pulses generated by the RFID label can be read by the reader  76 . Product label  78  covers RFID label  72 . 
       FIGS. 5-6  show alternate embodiments of blow molded containers with RFID labels integrally connected thereto.  FIG. 5  shows container  80 , similar in configuration to container  70  of  FIG. 4 ; however, RFID label  82  is integrally connected to base portion  84  of container  80  rather than to side wall portion  86 .  FIG. 6  shows container  90 , which is also a blow molded container; however, RFID label  92  is integrally connected to neck portion  94  rather than sidewall portion  96  or base portion  98 . 
     The RFID system can be integrally applied to a desired article as described above, as a plastic container, pallet, or other desired articles, to create a highly advantageous assembly. 
     Thus, for example, the above article-chip-antenna assembly can be used for inventory control, to automatically bill customers when they leave the store, for product temperature control, to alter product label designations, to track container returns, to alert one to product expiration dates, and many other uses. Moreover, this can be accomplished simply and expeditiously with a maximum of convenience for the store and customer. 
     Advantageously, the RFID label or transponder does not require direct contact or line of sight with the reader. The transponder simply is a device that generates electrical signals or pulses that are interpreted by the reader. The reader is a transmitter-receiver combination (transceiver) that activates and reads the identification signals from the transponder. 
     A part of the reader is preferably a microprocessor with functions that include decoding, performing simple calculations and forwarding the information to a computer system for record keeping and processing. The RFID label or tag is preferably an integrated circuit that is coupled to a small antenna to transmit data. The circuit contains a memory chip or computer chip that stores the pertinent data to be transmitted when the chip is activated. The reader can be either hand held or a stationary unit. 
     The tagging system may be classified by RF frequency bands, with high, intermediate and low frequency ranges. A low frequency transponder generates a strong and broad signal spread, and this would be preferred for the present application. It requires a shorter distance to communicate with the reader, typically no more than 10 feet and moving at a speed less than 20 miles an hour. 
     The medium range would not be as popular for tagging. This range is widely used by citizen band radios, automatic door openers and remote control toys, thus possibly interfering with other applications. However, many tagging applications, such as inventory control or asset tracking may rely on this range because of its versatility and strength. 
     High frequency systems are particularly suitable, for example, in the automobile and trucking industries. These systems often can communicate with readers at a distance greater than 250 feet while moving at speeds of more than 150 miles per hour. 
     RFID systems may also be categorized by their tag characteristics being active or passive. 
     Active tags include a power source, such as a battery. Advantages are a longer read range and a reduced power requirement. Disadvantages include limited operating life, inability to be used in all environments and a cost exceeding that of passive tags. Thus, for example, one can employ integral power means, as power paper systems where the chip and antenna system is similar to  FIGS. 2 and 3 , but are printed on thin film lithium, zinc manganese dioxide, or a zinc carbon system, on a substrate. The substrate could be a variety of things, as paper, polyester, fabric, etc. The chip and antenna would be applied to or printed on this powered substrate. One could also use a small battery which could be attached to an RFID label, but his would be bulkier than a film power source. 
     Passive tags have no integrated power source, but do have a chip and antenna, and these would be preferred for the present application. Thus, they are powered electromagnetically by the reader. Advantages are lower cost, a considerably smaller and lighter size, and a virtually unlimited life. However, they have a short read range of up to one meter and a higher powered reader is required to activate them. 
     The integral RFID labels of the present invention can be used to respond to conditions outside programmed parameters. For example, an RFID label of the present invention on a food item package can be set like a thermostat to signal when the temperature exceeds the point where thawing or spoiling begins. Also, the RFID labels in accordance with the present invention can be used where a bar code doesn&#39;t work, can withstand intense heat and cold, and can even withstand chemical exposure. 
     In addition to the significant advantages referred to hereinabove, the RFID labels of the present invention can be read through up to two inches of non-metallic debris, including paint, plastic, cloth, wood, smoke, grime and concrete. Moreover, line of sight is not required as with a bar code. 
     Thus, for example, using the RFID labels of the present invention a shopper can push a full cart of bagged or unbagged groceries past a reader and have a receipt therefore printed within seconds. A debit or credit card can be scanned and the shopper can quickly leave the store with purchased goods. At the same time, inventory data at the store can be updated and other management information collected. A rapid and efficient shopping system is thereby provided in a safe and effective manner. 
     It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope.