Patent Publication Number: US-2010130288-A1

Title: Rfid-incorporated game token and manufacturing method thereof

Description:
TECHNICAL FIELD 
     The present invention relates to tokens for use in games and more particularly to an RFID-incorporated game token. 
     BACKGROUND ART 
     In recent years, as the development of RFID tags has been advanced, the incorporation of an RFID tag in a token for a game has been suggested. For example, U.S. Pat. No. 6,659,875 discloses the arrangement in which an IC chip and an antenna are directly adhered to the backside of the front surface label of a token. 
     DISCLOSURE OF THE INVENTION 
     Problems to be Solved by the Invention 
     However, in the arrangement disclosed by U.S. Pat. No. 6,659,875, the IC chip can easily be removed or replaced by a different IC chip by peeling off the front surface label. Since the IC chip and the antenna are directly adhered to the backside of the front surface label, the IC chip can easily be damaged when the token is manufactured or used. In view of the problem, it is therefore an object of the present invention to provide a game token that does not allow an RFID tag to be easily removed and hardly has failures in the RFID tag during manufacturing or in use. 
     Means for Solving the Problems 
     In order to achieve the above-described object, a game token according to the present invention includes resin plates, and an RFID tag held between the resin plates while it is covered with sheets having flexibility or plasticity. 
     In this arrangement, the RFID tag is held between the resin plates, and the RFID tag cannot easily be removed. It can also resist externally applied stress. The RFID tag is covered with sheets having flexibility, and therefore when the RFID tag is held between the resin plates, the RFID tag can be prevented from being damaged in the fixing step for example by thermal press-bonding of the resin plates. Therefore, a game token that does not allow an RFID tag to be easily removed and hardly has failures in the RFID tag during manufacturing or in use can be provided. 
     In the game token according to the present invention, the material of the sheet is preferably paper. Alternatively, it is also preferable to use vinyl chloride or polyethylene terephthalate. 
     In the game token according to the present invention, the body may be rectangular or disk-shaped. 
     In the game token according to the present invention, the area of the RFID tag covered with the sheets is preferably smaller than the area of the resin plates. Alternatively, the resin plate may be extended to a side surface of the game token. In this way, the RFID tag is not exposed when viewed from the side surface of the game token, which aesthetically improves the appearance of the token. 
     In order to achieve the above-described object, by a method of manufacturing a game token according to the present invention manufactures a game token formed by holding an RFID tag covered with sheets between resin plates, the sheets have flexibility or plasticity, and the method includes the steps of forming a layered body by holding the RFID tag covered with the sheets having flexibility or plasticity between resin plates or resin films to be a material for the resin plates, and thermally press-bonding the layered body. 
     By the manufacturing method, the RFID tag is held between the resin plates, and therefore the RFID tag cannot be removed from the manufactured token and the token is resistant to externally applied stress. The RFID tag is covered with sheets having flexibility or plasticity, and therefore the RFID tag can be prevented from being damaged in the step of thermal press-bonding. Consequently, a game token that does not allow an RFID tag to be easily removed and hardly has failures in the RFID tag during manufacturing or in use can be provided. 
     By the method of manufacturing a game token according to the present invention, the step of forming the layered body preferably includes the step of holding a plurality of RFID tags between resin films or resin plates having a size corresponding to the plurality of RFID tags as the resin films or resin plates, and the method preferably further includes the step of cutting individual game tokens out from the thermally press-bonded layered body after the step of thermally press-bonding the layered body. 
     By the manufacturing method, a plurality of game tokens can be produced by a single thermal press-bonding step, and therefore a high yield is achieved. 
     By the method of manufacturing a game token according to the present invention, the step of forming the layered body includes the step of holding an RFID tag sheet between resin films or resin plates having a size corresponding to a plurality of RFID tags, the RFID tag sheet including the plurality of RFID tags covered with the flexible sheets, and the method preferably further includes the step of cutting individual game tokens out from the thermally press-bonded layered body after the step of thermally press-bonding the layered body. 
     By the manufacturing method, a plurality of game tokens can be produced by a single thermal press-bonding step and the step of cutting the RFID tags out from the RFID tag sheet is not necessary, so that an even higher yield is achieved. 
     Effects of the Invention 
     As in the foregoing, according to the present invention, a game token that does not allow an RFID tag to be easily removed and hardly has failures in the RFID tag during manufacturing or in use can be provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a perspective view of a chip according to a first embodiment of the present invention. 
         FIG. 1B  is a sectional view taken along A-A′ in  FIG. 1A . 
         FIG. 2  is a partly cutaway plan view of the structure of a core incorporated in the chip according to the first embodiment. 
         FIGS. 3A to 3C  are views schematically showing main manufacturing steps for a core. 
         FIG. 4  is an exploded perspective view showing an example of a method of manufacturing the chip according to the first embodiment. 
         FIG. 5  is an exploded perspective view of another example of the method of manufacturing the chip according to the first embodiment. 
         FIG. 6  is an exploded perspective view showing yet another example of the method of manufacturing the chip according to the first embodiment. 
         FIGS. 7A and 7B  are exploded perspective views showing a further example of the method of manufacturing the chip according to the first embodiment. 
         FIGS. 8A to 8C  are views schematically showing main manufacturing steps for a chip according to a second embodiment of the present invention. 
         FIG. 9  is a sectional view showing the structure of the chip according to the second embodiment. 
         FIGS. 10A to 10C  are views schematically showing main manufacturing steps for a chip according to a third embodiment of the present invention. 
         FIG. 11  is a sectional view showing the structure of the chip according to the third embodiment. 
         FIGS. 12A to 12C  are views schematically showing main manufacturing steps for a chip according to a fourth embodiment of the present invention. 
         FIG. 13  is a sectional view showing the structure of the chip according to the fourth embodiment. 
         FIGS. 14A to 14C  are views schematically showing main manufacturing steps for a chip according to a modification of the fourth embodiment of the present invention. 
         FIG. 15  is a sectional view of the structure of the chip according to the modification of the fourth embodiment. 
         FIGS. 16A and 16B  are sectional views showing the structure of a chip according to a fifth embodiment of the present invention. 
         FIG. 17  is a sectional view showing the structure of a chip according to a modification of the fifth embodiment. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Now, embodiments of the present invention will be described in detail in conjunction with the accompanying drawings. 
     First Embodiment 
       FIG. 1  shows the structure of a game token (hereinafter referred to as “chip”)  10  according to a first embodiment of the present invention.  FIG. 1A  is a perspective view of the chip  10  and  FIG. 1B  is a sectional view of the chip  10  taken along A-A′ in  FIG. 1A . Note that in  FIGS. 1A ,  1 B and  2  and the other figures, elements of each chip are not drawn in actual size. For example, in  FIG. 1B , the thickness of the elements inside the chip is emphasized for ease of illustration of the inside structure of the chip. 
     As shown in  FIGS. 1A and 1B , the chip  10  according to the first embodiment includes two rectangular resin plates  11  and a core  12  held between the two resin plates  11 . The core  12  includes an RFID tag  121  and cover sheets  122  that cover the entire RFID tag  121 . The resin plates  11  are formed by providing resin films of a material such as vinyl chloride and polyethylene terephthalate upon each other and thermally press-bonding them. A number, a sign, a pattern or the like corresponding to the value of the chip  10  is printed on the surfaces of the resin plates  11  in some cases. Alternatively, a label or protection layer made of the same material/a different material as/from the resin plates  11  may be adhered on the surfaces of the resin plates  11 . 
     Now, with reference to  FIG. 2 , the structure of the core  12  will be described. As described in conjunction with  FIG. 1 , the core  12  includes the RFID tag  121  and the cover sheets  122  that cover the RFID tag  121 . As shown in  FIG. 2 , the RFID tag  121  is formed by having an IC chip  121   a  and an antenna  121   b  provided on a single base film  121   c  or held between two base films  121   c . Note that how to connect the IC chip  121   a  and the antenna  121   b  in the RFID tag  121  and the pattern shape or the like of the antenna  121   b  on the base film  121   c  are arbitrary and not limited to the arrangement shown in  FIG. 2 . 
     The IC chip  121   a  can be recorded with various kinds of information. Examples of such information include information indicating the value of the chip  10 , information indicating the manufacturer of the chip  10 , information indicating the owner of the chip  10 , information indicating the date of manufacture of the chip  10 , information indicating the date on which the chip  10  was obtained by the owner, information indicating the period in which the chip  10  can effectively be used and information indicating the place where the chip  10  can effectively be used. Needless to say, information that can be recorded on the IC chip  121   a  is not limited to the above-described examples. 
     The cover sheet  122  is a sheet used to cover the entire RFID tag  121  and paper, vinyl chloride, polyethylene terephthalate, or the like is suitably used for the material. The cover sheets  122  serve to protect the RFID tag  121  during thermal press bonding with the resin plates  11 . The cover sheet  122 , as will be described, needs only have such a degree of flexibility or plasticity that it conforms to the surface of the RFID tag  121  and can adhere to the other cover sheet  122  around the RFID tag  121  when the sheets hold the RFID tag  121  therebetween. 
     Now, with reference to  FIG. 3 , an example of a method of manufacturing the core  12  will be described. In this example, an adhesive (not shown) is applied on a cover sheet  122 , a plurality of RFID tags  121  are arranged at prescribed intervals as shown in  FIG. 3A . Then, another cover sheet  122  is placed thereon, and then the two cover sheets  122  are laminated to each other by the adhesive. In this way, as shown in  FIG. 3B , an RFID tag sheet  123  having the plurality of RFID tags  121  held between the two cover sheets  122  is formed. Note that  FIGS. 3A and 3B  show examples only and the number of RFID tags  121  arranged on the cover sheet  122  is arbitrary. 
     Then, the cores  12  are cut from the RFID tag sheet  123  as shown in  FIG. 3C  by punching processing so that each core has a contour slightly larger than the contour of the RFID tag  121 . Through the above-described steps, the cores  12  are produced. 
     In the example shown in  FIG. 3 , the RFID tag  121  is directly held between the two cover sheets  122 , but a cushion member (not shown) may be interposed between the RFID tag  121  and at least one of the two cover sheets  122 . This is because the use of the cushion material can prevent problems such as disconnection of the antenna  121   b  and connection failures between the IC chip  121   a  and the antenna  121   b  when stress is applied for example in the process of incorporating the core  12  between the resin plates  11 . Alternatively, for the same purpose, the cover sheet  122  itself is preferably a cushiony material. In another example, the adhesive may be applied thickly, so that the adhesive serves as a cushion material. 
     In the example shown in  FIG. 3 , the plurality of RFID tags  121  that have been separated in advance are arranged on the cover sheet  122 , but a plurality of IC chips  121   a  and a plurality of antennas  121   b  may be formed at prescribed intervals on a single large base film  121   c  and the whole structure may be held between two cover sheets  122 , followed by adhesion, and the cores  12  may be obtained by punching. 
     The core  12  obtained in this way is held between a plurality of resin films  11   a  as shown in  FIG. 4  and subjected to thermal press-bonding, so that the chip  10  having the sectional structure shown in  FIG. 1B  is completed. More specifically, the plurality of resin films  11   a  are thermally press-bonded to form the resin plates  11  that have the core  12  held therebetween. Note that in the example shown in  FIG. 4 , five such resin films  11   a  are each layered on and under the core  12 , while the number of resin films to be layered is not limited to the above example. 
     In the example in  FIG. 4 , the plurality of resin films  11   a  are arranged on and under the core  12  and subjected to thermal press-bonding, while as shown in  FIG. 5 , two preformed resin plates  11   b  may be prepared, and the core  12  may be held between the two resin plates  11   b  and subjected to thermal press-bonding or adhered by an adhesive. Note that the resin plate  11   b  may be formed by thermal press-bonding a plurality of resin films or by injection molding. In the step shown in  FIG. 5  as compared to the step shown in  FIG. 4 , the time during which the RFID tag  121  is subjected to the heat and pressure can be reduced, so that the RFID tag  121  can be prevented from being damaged and the yield can be improved. 
     As in the foregoing, the chip  10  according to the present embodiment has the RFID tag  121  held between the two resin plates  11 . Therefore, the RFID tag  121  cannot be removed from the chip  10 . The RFID tag  121  is covered with the cover sheets  122  and therefore the RFID tag  121  can be prevented from being damaged when the core  12  is held between the resin films  11   a  or the resin plates  11   b  and subjected to thermal press-bonding. 
     In the foregoing description, the chip  10  has a rectangular shape by way of illustration, but the outer shape of the chip is not limited to the rectangular shape, and the chip may have a disk shape as a modification of the first embodiment. 
     In the examples shown in  FIGS. 4 and 5 , the area of the core  12  is substantially equal to that of the resin film  11   a  or the resin plate  11   b , and therefore an end of the core  12  is exposed at a side surface of the chip  10  as shown in  FIG. 1B . In order to aesthetically improve the appearance of the chip  10 , the area of the core  12  is preferably made slightly smaller than that of the resin film  11   a  (or the resin plate  11 b) as shown in  FIG. 6 , so that the end of the core  12  does not appear at the side surface of the chip  10 . If the core  12  is sufficiently thin and the area of the core  12  is slightly smaller than the area of the resin film  11   a , the uniformity in the thickness of the chip  10  as a whole is not impaired. If the core  12  is relatively thick, rolling processing can be carried out with an amount of heat and a level of pressure that do not destroy the RFID tag  121  in order to equalize the thickness of the chip  10  as a whole. Alternatively, as shown in  FIG. 7A , resin covers  13  each having four side ends thicker than the center may be layered at the outer side of the resin films  11   a  and the covers and the resin films  11   a  may be thermally press-bonded, so that the thickness of the chip  10  as a whole is equalized. As shown in  FIG. 7B , the core  12  may be held between two resin plates  11   b ′ each formed to have four side ends thicker than the center, followed by thermal press-bonding or adhesion, so that the thickness of the chip  10  as a whole may be equalized. 
     Note that according to the present embodiment, the core is held between the two resin plates by way of illustration, but the number of resin plates arranged to hold the core therebetween is not limited to two. 
     Second Embodiment 
       FIGS. 8A to 8C  are schematic views showing the steps of manufacturing a chip according to a second embodiment of the present invention.  FIG. 9  is a sectional view of the structure of a chip  20  produced by the manufacturing steps shown in  FIGS. 8A to 8C . Note that the overall shape of the chip  20  may be rectangular or disk-shaped. The components described in connection with the first embodiment will be designated by the same reference characters and their detailed description will not be repeated. 
     As shown in  FIG. 9 , the chip  20  according to the second embodiment has a core  12  incorporated in a body  21  made of resin. The chip  20  is produced by the following steps. 
     To start with, as shown in  FIG. 8A , a plurality of cores  12  are arranged at prescribed intervals on a resin plate  21   b . The resin plate  21   b  may be formed by thermally press-bonding a plurality of resin films to each other or may be formed by injection molding. The number of cores  12  arranged on a single resin plate  21   b  is arbitrary. At the time, an adhesive may be applied on the resin plate  21   b  before the cores  12  are provided. Thereafter, another resin plate  21   b  is placed thereon and subjected to thermal press-bonding. In this way, as shown in  FIG. 8B , a layered body  22  including the two resin plate  21   b  having the cores  12  held therebetween is produced by fusion press-bonding. Then, as shown in  FIGS. 8C and 9 , the layered body  22  is cut into pieces in a prescribed size or cut by punching, so that rectangular chips  20  having RFID tags  121  incorporated in the bodies  21  are completed. 
     As in the foregoing, the chip  20  according to the present embodiment has the RFID tag  121  incorporated in the body  21 . Therefore, the chip  20  cannot be removed from the RFID tag  121 . The RFID tag  121  is covered with cover sheets  122 , and therefore the RFID tag  121  can be prevented from being damaged when the core  12  is held between the resin plates  21   b  and subjected to thermal press-bonding. 
     By the method according to the second embodiment, a plurality of chips  20  can be produced by a single thermal press-bonding step, so that the yield is higher than that in the first embodiment. 
     Note that in  FIG. 8 , the core  12  is held between the two resin plates  21   b  by way of illustration, while a plurality of resin films to be laminated may have a core  12  therebetween as shown in  FIG. 4  in connection with the first embodiment, and the structure may be thermally press-bonded at a time. The number of resin plates or resin films used to hold the core  12  is arbitrary. 
     Third Embodiment 
       FIGS. 10A to 10C  are schematic views showing the steps of manufacturing a chip according to a third embodiment of the present invention.  FIG. 11  is a sectional view of the structure of a chip  30  produced by the manufacturing steps shown in  FIGS. 10A to 10C . Note that the overall shape of the chip  30  may be rectangular or disk-shaped. 
     As shown in  FIG. 11 , the chip  30  according to the third embodiment has a core  12  held between two resin plates  31 . As can be understood from comparison between  FIGS. 1B and 11 , the chip  30  according to the third embodiment has the same structure as the chip  10  according to the first embodiment but their manufacturing methods are different. The chip  30  is produced by the following steps using an RFID tag sheet  123  shown in  FIG. 3B  in connection with the first embodiment. 
     To start with, as shown in  FIG. 10A , two large resin plates  31   b  having a size equal to a plurality of resin plates  31  are prepared, and an RFID tag sheet  123  is arranged between the two plates, followed by thermal press-bonding. Note that the resin plate  31   b  may be formed by thermally press-bonding a plurality of resin films or formed by injection molding. In this way, as shown in  FIG. 10B , a layered body  32  including the RFID tag sheet  123  held between the two resin plates  31   b  is formed. Then, the layered body  32  is cut or punched into pieces in a prescribed size, and a rectangular chip  30  having an RFID tag  121  held between the two resin plates  31  is completed as shown in  FIGS. 10C and 11 . 
     As in the foregoing, the chip  30  according to the present embodiment includes the RFID tag  121  held between the two resin plates  31 . Therefore, the RFID tag  121  cannot be removed from the chip  30 . The RFID tag  121  is covered with cover sheets  122 , and therefore the RFID tag  121  can be prevented from being damaged when the RFID tag sheet  123  held between the resin plates  31   b  is subjected to thermal press-bonding. 
     By the method according to the third embodiment, a plurality of chips  30  can be produced by a single thermal press-bonding step and the step of cutting the RFID tags  121  from the RFID tag sheet  123  by punching is not necessary, so that the yield is higher than those by the methods according to the first and second embodiments. 
     Note that in  FIG. 10 , the RFID tag sheet  123  is held between the two resin plates  31   b  formed by laminating the resin films in advance by way of illustration, but as shown in  FIG. 4  in connection with the first embodiment, the RFID tag sheet  123  may be held between a plurality of resin films before lamination and subjected to thermal press-bonding at a time. 
     Fourth Embodiment 
       FIGS. 12A to 12C  are views schematically showing the steps of manufacturing a chip according to a fourth embodiment of the present invention.  FIG. 13  is a sectional view of the structure of the chip  40  produced by the manufacturing steps shown in  FIGS. 12A to 12C . Note that the overall shape of the chip  40  may be rectangular or disk-shaped. 
     As shown in  FIG. 13 , in the chip  40  according to the fourth embodiment, a core  12  including an RFID tag  121  is embedded in a resin layer  41 , and the entire outer part of the resin layer  41  is covered with an upper cover  42  and a lower cover  43  made of resin. The upper cover  42  is arranged to cover one main surface and four side surfaces of the resin layer  41 . The lower cover  43  is arranged to cover the other main surface of the resin layer  41 . In  FIG. 13 , for ease of illustration of the sectional structure, the boundary line between the upper and lower covers  42  and  43  and the resin layer  41  and the boundary line between the upper and lower covers  42  and  43  are indicated. However, the resin is fused to integrate the upper cover  42 , the lower cover  43  and the resin layer  42  in some cases and the boundary lines between them may not be clearly defined in such cases. 
     Now, with reference to  FIGS. 12A to 12C , the steps of manufacturing the chip  40  will be described. As shown in  FIG. 12A , a plurality of resin films  41   a  are provided on a flat resin plate  45  as a material for the lower cover  43  with a core  12  interposed therebetween. A large resin plate  44  as a material for the upper cover  42  is provided thereon. Note that at the back surface of the resin plate  44 , rectangular recessed parts  44   a  each slightly smaller than the main surface of the chip  40  and raised parts  44   b  that define the recessed parts  44   a  are formed. More specifically, the resin film  41   a  has substantially the same area as that of the recessed part  44   a  so that the resin films  41   a  are fitted into the space formed by the recessed part  44   a  between the resin plates  44  and  45  when these plates are press-bonded. 
     When the resin plates  44  and  45  are thermally press-bonded, the resin of the resin films  41   a  is fused, and as shown in  FIG. 12B , a resin layer  41  that fills the space formed by the recessed part  44   a  between the resin plates  44  and  45  is formed. Therefore, the material for the resin film  41   a  is preferably resin that can be fused about at temperatures at which the RFID tag  121  is not destroyed. Then, as shown in  FIG. 12C , cutting is carried out along the raised parts  44   b , so that the chip  40  having the structure shown in  FIG. 13  is completed. 
     As in the foregoing, in the chip  40  according to the present embodiment, the RFID tag  121  is embedded in the resin layer  41 , the outer side of the resin layer  41  is covered with the upper and lower covers  42  and  43 . Therefore, the RFID tag  121  cannot be removed from the chip  40 . The RFID tag  121  is covered with cover sheets  122 , and therefore the RFID tag  121  can be prevented from being damaged when the resin films  41   a  are thermally press-bonded. By the method according to the present embodiment, a plurality of chips  40  can be produced by a single thermal press-bonding step, so that a high yield is achieved. 
     Note that in  FIG. 13 , the lower cover  43  has a flat plate shape and covers only one main surface of the chip  40  while a modification as shown in  FIG. 15  can also be employed. In the chip  40 ′ according to the modification shown in  FIG. 15 , one main surface of the chip and the upper half of four side surfaces are covered with an upper cover  48  and the other main surface and the lower half of the four side surfaces are covered with a lower cover  49 . As shown in  FIGS. 14A to 14C , the chip  40 ′ can be produced by the same steps as those shown in  FIGS. 12A to 12C  by using resin plates  46  and  47  symmetrical to each other in the vertical direction instead of the resin plates  44  and  45  shown in  FIG. 12 . 
     Fifth Embodiment 
       FIG. 16A  is a sectional view of the structure of a chip  50  according to a fifth embodiment of the present invention. The overall shape of the chip  50  may be rectangular or disk-shaped. 
     As shown in  FIG. 16A , a core  52  having an RFID tag  121  incorporated therein is held between two resin plates  51 . The core  52  has the RFID tag  121  held between sheets  522  with plasticity and has a substantially uniform thickness. Therefore, when the core  12  is held between the resin plates  51 , the thickness of the chip  50  as a whole is substantially uniform. Paper or resin for example may be used for the material of the sheets  522 . 
     Note that like a chip  50 ′ shown in  FIG. 16B , an RFID tag  121  may be embedded in a single sheet  522  having plasticity so that the tag does not protrude beyond the surface and the resulting structure may be held between two resin plates  51 . 
     Alternatively, like a chip  54  shown in  FIG. 17 , a core  53  including an RFID tag  121  between two sheets  532  through an adhesive layer  533  may be formed, and the core  53  may be held between two resin plates  51 . The adhesive layer  533  can adhere the two sheets  532 , absorb the thickness of the RFID tag  121  and equalize the thickness of the core  53 . 
     As in the foregoing, according to the present embodiment, the RFID tag  121  is held between the two resin plates  51 . Therefore, the RFID tag  121  cannot be removed from the chip. The RFID tag  121  is covered with cover sheets  522  or  532 , and therefore the RFID tag  121  can be prevented from being damaged when the core  52  or  53  and the resin plates  51  are thermally press-bonded. 
     INDUSTRIAL APPLICABILITY 
     The present invention has industrial applicability in the field of game tokens.