Patent Description:
In the retail industry, it would be advantageous to provide sensor tags, such as RFID tags, which can be attached to textile or other items so that the sensor tag becomes an integrated (and difficult to detect) part of the item. In some aspects, for example, it would also be advantageous to provide a sensor tag for garments and the like that is designed to be attached to the garment permanently. Such a tag would need to be highly water resistant so as to be impervious to repeated washings.

One drawback of tagging goods with RFID and other sensor devices for purposes of theft prevention is that the tag itself is often visible to thieves. Shoplifters in many cases are able to locate the RFID tag and simply remove, disable, or shield an RFID element to evade detection by exit portal RFID readers.

A less obtrusive, smaller, and harder to detect RFID solution is needed, in particular due to the increasing importance of a Radio Frequency Identification (RFID) technology for retail logistics.

Some known systems use electronic thread technologies allowing for electronics to be integrated into textiles. In one aspect, microelectronic components (such as RFID chips) may be attached to a fabric using conductive thread (e-thread) which is woven into the fabric. The e-thread provides the metal antenna for the RFID chip. In another aspect, a pattern of conductive ink may be applied to fabric to create an electronic circuit including electronic components attached to the fabric. Yet another aspect allows fully-functional, self-contained electronic components to be entirely sheathed within a segment of thread or yarn. These segments of thread or yarn may be woven into the textiles. In one example, an RFID chip, antennas, and associated energy-harvesting circuitry may be included within a segment of thread or yarn. In still other examples, other loss prevention technologies may be included within a portion of thread or yarn.

Document <CIT> discloses a manufacturing method for a textile RFID tag. A plastic tag is applied on a flexible substrate layer (for example film of polyurethane over a fabric layer), the plastic tag is encapsulated between two layers made of a thermally sealable dielectric material and polyurethane respectively. The multilayer tag is applied on a product by thermo-pressing. Document <CIT> discloses a method for manufacturing an RFID tag including a loop region, a dipole region and an RFID chip between said loop region and dipole region, a protective layer covers and protects the dipole region.

Document <CIT> discloses an RFID tag and a method for attaching the tag to a flexible substrate. A heat fusible layer including adhesive layers, antenna layers and further layers is provided for holding the RFID tag. The heat fusible label comprising the RFID tag is applied to the flexible surface by heat and pressure.

Document <CIT> discloses fabric RFID labels for mounting on garments, the label comprising an RFID inlay and several functional sheets which can also be made with TPU.

It would be highly advantageous to insert an RFID tag and antenna directly into the textile product/clothing garment that is intended to be protected by the RFID tag. As described above, known techniques include sheathing the RFID component into a thread or yarn that can be sewn into the cloth. However, it has been difficult and requires a special machine to install the thread into the clothing. In order to have physical strength, the wire is coated by a thick coating. This causes the thread to be felt by someone touching the garment, and the thread can be seen after the garment has been ironed. In addition, the cost of this solution is high. The RFID-containing wires in the current solutions are thick and do not meet the customer needs.

The present disclosure provides systems, apparatuses, and methods for providing sensor tags that are sealed and flexible.

In an aspect, a method for configuring a sensor tag according to claim <NUM> or claim <NUM> is disclosed.

In another aspect, a sensor tag according to claim <NUM> is disclosed.

In some instances, well known components may be shown in block diagram form in order to avoid obscuring such concepts.

Aspects of the present disclosure provide a sensor tag, such as a passive RFID tag, which is thin, flexible, and highly water-resistant, and can be discreetly attached to or otherwise incorporated into many different types of items. The flexible, water-resistant sensor tag is particularly suitable to be incorporated into textile items, such as garments, and can be discreetly disposed within the item so as to be concealed from view. The sensor tag can be submersed in water without damage to the sensor inlay, and can withstand repeated laundering.

Turning now to the figures, example aspects are depicted with reference to one or more components described herein, where components in dashed lines may be optional.

Referring to <FIG>, in one non-limiting aspect, a flexible, water-resistant sensor tag <NUM> includes a sensor <NUM> disposed between a flexible substrate layer <NUM> and a coating layer <NUM>. In some aspects, the sensor <NUM> may be an RFID sensor. However, the present aspects are not limited to an RFID sensor, and any combination and number of different sensors within a single sensor tag may be desirable for each specific application. For example, in some aspects, the sensor <NUM> may include more than one sensor, and each sensor may be an RFID sensor or may be another type of sensor. In some non-limiting aspects, for example, the sensor <NUM> may include one or more Electronic Article Surveillance (EAS) sensors instead of or in addition to one or more RFID sensors, and each EAS sensor may emit a detectable signal in response to an interrogation field. In some non-limiting aspects, for example, the sensor <NUM> may include one or more Near-field communication (NFC) and/or one or more acousto-magnetic (AM) sensors instead of or in addition to one or more RFID sensors and/or one or more EAS sensors.

In an aspect, for example, the sensor <NUM> may include an RFID inlay including an integrated circuit (IC) connected to an antenna <NUM>. The RFID inlay may be affixed/applied to the flexible substrate layer <NUM>, which may have a polymer thick film composition. In one non-limiting aspect, for example, the flexible substrate layer <NUM> may be made of thermoplastic polyurethane (TPU). In one non-limiting aspect, the antenna <NUM> may be printed onto the TPU substrate using conductive ink. Then, a second protective polymer layer preferably made of a flexible material such as TPU may be applied as a protective overcoat over the sensor <NUM> to provide the coating layer <NUM>. Accordingly, a sealed encapsulating TPU layer is formed to house the RFID inlay.

In an alternative aspect, the flexible substrate layer <NUM> may be made of fabric, woven cloth, or any other type of flexible, sew-able material. In some aspects, a stretchable, semi-elastic type of cloth fabric may be particularly suitable for the flexible substrate later <NUM>. The sensor <NUM> may be applied to the fabric substrate, and then a thin, protective polymer layer, such as TPU, may be applied over the fabric substrate to seal the RFID inlay between the fabric and the TPU.

As described above, a TPU layer may be applied to provide the coating layer <NUM> over the RFID inlay. Alternatively, referring to <FIG>, in aspects where the flexible substrate layer <NUM> is made of fabric, a TPU coating may be applied to both sides of the fabric substrate to provide an encapsulating layer <NUM> that provides a protective, sealed, water-resistant housing for the electronic components applied to the fabric substrate. In some non-limiting aspects, the encapsulating layer <NUM> is a protective coating layer of TPU that can be positioned on the fabric substrate so that the sensor tag <NUM> has an edge portion providing a TPU-free margin. This edge portion which does not have a TPU coating may be used as the sewing edge when the sensor tag <NUM> is sewn into the garment.

In aspects where fabric is used for the flexible substrate layer <NUM>, conductive inks may be used to print the antenna <NUM> directly on the fabric. Alternatively, the fabric may include conductive threads which are woven into the fabric to provide the antenna <NUM>. In some aspects, the conductive thread may be woven into the fabric to provide some degree of elasticity so that the conductive traces are stretchable.

Referring to <FIG>, in yet another alternative aspect, the flexible substrate layer <NUM> may be made of fabric, or any other type of flexible, sew-able material, and the flexible substrate layer <NUM> may have a thin film of TPU <NUM> applied to at least one side such that the TPU film <NUM> provides a substrate for the application of the sensor <NUM>. After the electronic components (e.g., the sensor <NUM>, the antenna <NUM>, etc.) are applied to the TPU film <NUM>, another layer of TPU may be applied to provide the coating layer <NUM> and thereby encapsulate the sensor <NUM> between two TPU layers: (<NUM>) the coating layer <NUM>; and (<NUM>) the TPU film <NUM> on the fabric substrate. In some aspects, the TPU film <NUM> and/or the coating layer <NUM> may be positioned on the fabric substrate such that the sensor tag <NUM> has a fabric edge portion providing a TPU-free margin. This edge portion which does not have a TPU coating may be used as the sewing edge when the sensor tag <NUM> is sewn into a garment.

In the present aspects, the sensor tag <NUM> may be flexible, bendable, stretchable, or otherwise configured/constructed to sustain deformations. Also, the flexibility of the sensor tag <NUM> allows for the sensor tag <NUM> to be constructed and arranged so that the aforementioned deformations do not negatively affect the functionality and operation of the electronic components disposed within the sensor tag <NUM> (e.g., the sensor <NUM>, the antenna <NUM>, etc.).

In some aspects, the sensor tag <NUM> may be manufactured to satisfy standards of environmental sustainability. For example, in some aspects, a natural-fiber fabric may be used as the flexible substrate layer <NUM> (or as a portion of the flexible substrate layer <NUM>) so that the sensor tag <NUM> incorporates less plastic material than conventional sensor tags. For example, the sensor tag <NUM> may be manufactured using natural-fiber fabric substrates that are sustainable in nature, particularly if the fabric is non-polyester. In some alternative aspects, the flexible fabric substrate may be made of a textile manufactured from recycled plastics, thus allowing the sensor tag <NUM> to be manufactured to satisfy sustainability requirements.

As described herein, in some aspects, the sensor <NUM> disposed in the sensor tag <NUM> may be any type of sensor. For example, in an aspect, the sensor <NUM> may be an EAS sensor or an RFID sensor. In some further aspects, the sensor tag <NUM> may include more than one sensor of the same type or of different types. For example, referring to <FIG>, in one non-limiting aspect, the sensor tag <NUM> may include a first sensor <NUM> and a second sensor <NUM>, where the first sensor is an RFID sensor and the second sensor <NUM> is an EAS sensor. Accordingly, the sensor tag <NUM> has dual technology functionality (both RFID and EAS).

In an aspect, the EAS sensor may be a sensor of the type used in Acousto Magnetic (AM) systems. In one non-limiting aspect, for example, the detectors in an AM system emit periodic bursts at <NUM>, which causes a detectable resonant response in an AM tag. A security tag in a <NUM> system may also be implemented as an electric circuit resonant at <NUM>. In an aspect, the EAS sensor to be incorporated into the sensor tag <NUM> may have a small and substantially flat form factor, and may have a degree of flexibility.

In <FIG>, in order to manufacture the sensor tag <NUM>, both the first sensor <NUM> and the second sensor <NUM> may be applied to the flexible substrate layer <NUM>. Then, a coating layer <NUM> of TPU may be applied onto both the first sensor <NUM> and the second sensor <NUM> to provide a sealing layer of TPU coating.

In some aspects, the sensor tag <NUM> described herein with reference to various aspects may be configured to be flexible and also impervious to detergents, water, grease, oil, dirt, harsh chemicals, etc. In some non-limiting aspects, for example, the sensor <NUM> within the sensor tag <NUM> includes an RFID inlay that provides flexibility so that the chip and antenna of the RFID inlay can be repeatedly stretched and deformed without damaging the functionality of the sensor <NUM>.

In some non-limiting aspects, the sensor tag <NUM> described herein with reference to various aspects may be attached to, or otherwise incorporated into, any type of apparel and garments, handbags, belts, shoes, caps, hats, scarves, ties and other accessory items, etc. For example, in one non-limiting aspect, the sensor tag <NUM> may be hidden behind the seams of running shoes. The sensor tag <NUM> may also be used for household-type textiles, such as bed furnishings, window curtains, pillows, furniture cushions, blinds, table cloths, napkins, etc. The sensor tag <NUM> may also be incorporated into camping tents and textile utility items, such as tarps. The sensor tag <NUM> is also suitable for application to rubber or plastic goods. While the sensor tag <NUM> may be particularly suitable for attachment to goods of a flexible, pliant nature (such as textiles), the sensor tag <NUM> may also be attached to hard goods. In an aspect, for example, in use with hard goods, the sensor tag <NUM> may be positioned in an interior portion of an item, such as an inaccessible interior cavity. It will be understood that a list of possible applications for the sensor tag <NUM> would be exhaustive in nature, and are not limited to those mentioned herein.

In some aspects, the sensor tag <NUM> described herein with reference to various aspects may be integrated into an item in such a way that the sensor tag <NUM> is hidden or wholly undetectable when attached to the item. For example the sensor tag <NUM> may be discretely sewn into a garment. The sensor tag <NUM> may also be disposed in the hem, in a seam, in a shirt collar, in a waistband, etc. The sensor tag <NUM> may be constructed using a soft, flexible substrate (e.g., TPU and/or fabric) and a sealing layer which is a flexible material coating (e.g., TPU). Since the sensor tag <NUM> is soft and flexible, a person wearing or handling the item to which the sensor tag <NUM> is attached may not feel the presence of the sensor tag <NUM>. This also ensures that the sensor tag <NUM> will not irritate a person's skin by continued contact with protruding components.

In some aspects, the sensor tag <NUM> described herein with reference to various aspects may also be constructed to visually blend with an article. For example, if a fabric substrate is used, the fabric substrate may be chosen to be the same color as the item to which the sensor tag <NUM> is attached. The flexible fluid resistive material lay may be a colored TPU material which matches the color of item to which the sensor tag <NUM> is attached. In some aspects, the sensor tag <NUM> may also be suitable for integration into a brand label since the TPU can be colorless or can be a specific color that merges with a background color and be discrete. For example, in an aspect, the brand logo may be thermal printed on one side of a brand label, and the sensor tag <NUM> may be heat sealed to the opposite side of the brand label. Since the sensor tag <NUM> is configured to avoid bleed through into the substrate, the application of the sensor tag <NUM> to the brand label will not disturb the brand logo.

In some aspects, after application to an item, the sensor tag <NUM> described herein with reference to various aspects may be used in many different types of systems where data communication with the sensor tag <NUM> is desired. In an aspect, for example, the sensor tag <NUM> may be configured to facilitate inventory management. In this regard, the sensor tag <NUM> may be configured for allowing data to be exchanged with an external device, such as a tag reader, via wireless communication technology. In addition to the RFID inlay and the EAS sensor described above, the electronics incorporated into the textile may enable any suitable radio communications protocol for a given mode of use, such as Short Range Communications (SRC), Near Field Communication (NFC), Bluetooth, ZigBee, etc..

In one non-limiting aspect, for example, the sensor tag <NUM> described herein with reference to various aspects may include an RFID sensor, and the presence of the sensor tag <NUM> within a garment may be a part of a Return Authenticity system as may be implemented by a retailer. In another non-limiting aspect, for example, the data communications capability of the sensor tag <NUM> may also be utilized by individuals who have purchased the item to which the sensor tag <NUM> is attached. The durability of the sensor tag <NUM> may allow for utilizing the sensor tag <NUM>, which remains embedded within the item to which the sensor tag <NUM> is attached, long after the item has been purchased. To this end, the sensor tag <NUM> may be configured to withstand multiple wash/dry cycles as would occur during normal use of a tagged garment.

For example, in one non-limiting aspect, a tag reader device may be used in a household environment to read data from the sensor tag <NUM>, thus enabling a person to precisely locate a certain item using a tag reader device. In another aspect, for example, a home closet may be configured to read the tags of garments located within the closet, thus allowing an individual to instantly electronically inventory their own personal belongings.

In an aspect, the sensor tag <NUM> described herein with reference to various aspects may be configured to conform to privacy laws regarding personal consumer data, which may vary by jurisdiction. For example, in European Union (EU) countries, consumer data collection needs to comply with the General Data Protection Regulation (GDPR). In this case, the sensor tag <NUM> may be brought into GDPR compliance by selecting an RFID chip which is GDPR compliant.

The use of TPU material as described herein provides a sensor tag <NUM> having high degree of flexibility as compared to conventional tags which use polyethylene terephthalate (PET) as a substrate. The sensor tag <NUM> described herein with reference to various aspects may tolerate extreme deformation stresses in applications were conventional tags with PET substrates are not sufficiently elastic.

As described herein, in some aspects, the sensor tag <NUM> may incorporate TPU as both the inlay substrate and the protective coating, or may use TPU to envelope and seal an RFID inlay on another type of flexible, semi-distortable substrate. In aspects in which TPU material is used to form the flexible substrate layer <NUM>, a type of conductive ink that is compatible with TPU may be used to form the antenna <NUM>. Such suitable conductive inks may include, but are not limited to, inks incorporating electrically conductive powders such as silver metal powder, alloys of silver metal powder, or mixtures thereof. In some aspects, the antenna <NUM> may be formed by a conductive ink type that retains a stretchable, elastic quality after application to the flexible substrate layer <NUM>. This ensures that the circuit of the sensor <NUM> remains functional even when the sensor tag <NUM> is subjected to distortional stress.

In some aspects, the conductive ink may be applied to the substrate by screen printing, where the screen mesh size controls the thickness of the deposited thick film. In some alternative aspects, the conductive ink may be applied to the substrate by stencil printing, ink jet printing, or coating techniques. In one non-limiting aspect, for example, the conductive ink may be screen printed on a stretched substrate by dropping or depositing the conductive ink through a nozzle with a thickness of, e.g., <NUM> to <NUM> microns. In aspects where the stretched substrate is made of TPU, the substrate does not change shape after being released from the stretch, and therefore preserves the geometry of the antenna <NUM> that is printed thereon. In some aspect, the conductive ink may be a gelatinous liquid that does not spread beyond the intended printing area. In one non-limiting aspect, the antenna <NUM> formed by screen printing using a conductive ink may have a width of, e.g., <NUM> on a substrate having a width of <NUM>. In aspects where the sensor <NUM> includes an RFID sensor, a wider antenna may allow for a faster response time. In contrast, known systems that use a copper wire to form the antenna <NUM> are unable to provide a wide antenna. Since the antenna <NUM> in these aspects is formed by screen printing as opposed to chemical processes such as chemical etching, sustainability requirements are also satisfied.

As described herein, in some aspects where the flexible substrate layer <NUM> is made of TPU, the antenna <NUM> may be directly printed on TPU as the paste is interacting with TPU. Alternatively, in some aspects, an interlayer paste may be introduced on top of TPU, where the interlayer paste has a thickness of, for example, <NUM> microns to enable printing of the antenna <NUM> with silver ink and still maintain suppleness/flexibility. In some aspects, for example, a micro-silver ink may be used instead of or in addition to a nano-silver ink for screen printing the antenna <NUM> onto the TPU substrate.

In one non-limiting aspect, the antenna <NUM> may be formed in a meandering shape. Alternatively, the antenna <NUM> may be formed in a rectangular shape or as one or more straight strips of conductive ink. However, the shape of the antenna <NUM> is not limited to the above, and the antenna <NUM> may have a different shape or a combination of different shapes.

The applied conductive ink may then be oven dried or thermally cured. In one non-limiting aspect, for example, the conductive ink may be cured on a nylon or polyester fabric substrate through a progressive cure cycle. In this case, as the progressive cure cycle cures the conductive ink, the fabric substrate does not melt, while the conductive ink adheres to the fabric substrate but does not drain/seep through the fabric substrate.

In one non-limiting aspect, after the conductive ink is cured, a sensor chip may be configured on the flexible substrate layer <NUM> so as to make proper contact with the antenna <NUM> formed by the conductive ink. Then, a layer of polyurethane having a thickness of, e.g., about <NUM> microns, may be heat sealed (e.g., using a heat gun) to provide resistance/protection against abrasion, oil, water, grease, etc. In some aspects, the resulting sensor tag <NUM> may withstand, for example, two laundry washes at <NUM> with a typical detergent. In some aspects, the resulting sensor tag <NUM> may withstand processes such as ironing, bleaching, disinfecting, etc..

In an aspect, a plurality of sensor tags <NUM> described herein with reference to various aspects may be fabricated using an elongated single piece of substrate, which may be TPU, fabric, or fabric having a TPU film applied thereon. In an aspect, for example, a series of electronic components may be coupled to the substrate so as to be separated from each other with equal or unequal amounts of substrate. Then, a TPU coating layer may be applied to the entire length of the substrate which has the series of electronic components coupled thereon. The length of narrow substrate may then be cut into separate sensor tags <NUM> by an applicator machine at the time the sensor tags <NUM> are to be attached to an item.

In some aspects, as described herein with reference to various aspects, the one or more sensors <NUM> to be incorporated into the sensor tags <NUM> may be any type of sensor which can be produced with a relatively small, flat profile. In addition to the sensor types already described, the one or more sensors <NUM> may also include bio-sensors for detecting the physiological status of a person. For example, in an aspect, a sensor tag <NUM> embedded in a garment may include a sensor <NUM> configured to detect a wearer's heart rate. In another example aspect, a sensor tag <NUM> integrated into a garment may include a sensor <NUM> configured to sense a garment wearer's position (e.g., standing up, sitting, etc.). Other non-limiting example types of sensors <NUM> which can be incorporated into the sensor tag <NUM> are sensors which can sense the location of the wearer and/or the wearer's movement pattern (e.g., running, standing still, etc.). Suitable sensor implementations include, but are not limited to, a capacitive strain sensor, a conductive ink capacitive sensor, a conductive ink electrode sensor, a conductive ink resistive sensor, a fiber optic sensor, a metal electrode sensor, an optical sensor such as an optical probe sensor or an optical source sensor (e.g., a laser, a light emitting diode (LED), etc.), a piezo resistive strain gauge sensor, a semiconductor sensor (e.g., a force sensor, a gyroscope, a magneto-resistor sensor, a photodiode sensor, a phototransistor sensor, a pressure sensor, and/or a tri-axis accelerometer).

In some aspects, the sensor tag <NUM> described herein with reference to various aspects may have a flexible substrate layer <NUM> that is made of fabric (e.g., polyester, nylon, non-polyester material, etc.), TPU, rubber, etc..

In some aspect, the sensor tag <NUM> described herein with reference to various aspects may include an antenna <NUM> that is formed on the flexible substrate layer <NUM> using a conductive ink such as a silver or copper based ink. Unlike conventional sensor tags that implement an antenna using a wire that is either stitched or woven into a substrate and thus can easily be defeated or get disconnected, the antenna <NUM> in the present aspects is formed using a conductive ink and is therefore more robust. Further, conductive ink-based RFID sensors are relatively cheaper and faster to manufacture compared to RFID sensors with antennas formed with stitched thread or weaved thread into the substrate. In some aspect, the antenna <NUM> formed using a conductive ink on a fabric or TPU substrate is more flexible and less rigid and therefore causes less performance issues as compared to a copper thread woven or stitched into a substrate. For example, in cases where copper wire is woven or stitched into the substrate to form a conductor, wire stretch may cause a change in impedance and therefore may impact RFID read performance. In contrast, conductive ink based sensors are more robust to such stretch effects.

In some aspects where the flexible substrate layer <NUM> is made of fabric, the fabric may have a nylon taffeta or polyester taffeta weave that helps the conductive ink adhere on top of the substrate.

In some aspects where the flexible substrate layer <NUM> is made of fabric, the fabric may be a Polyurethane coated fabric (PU) that allows for forming the antenna <NUM> by deposition of conductive ink on the surface of the fabric without any seepage. In one non-limiting aspect, the coating layer <NUM> may be formed by applying another layer of such fabric on top of the base fabric on which the antenna <NUM> is printed. Accordingly, sealing/protection of the sensor <NUM> is provided by PU coating on the fabric against grease/oil, water, abrasion. Alternatively, the coating layer <NUM> may be formed by applying colorless or colored TPU on top of the fabric substrate on which the antenna <NUM> is printed. In an aspect, for example, colored TPU may be used for the coating layer <NUM> to hide the antenna <NUM>. In some aspects, for example, the thicknesses of the fabric substrate may be varied as per a use profile related to the integration needs of a garment.

In some aspects where the flexible substrate layer <NUM> is made of a polyester/satin fabric coated with polyurethane (e.g., PU fabric), the temperatures for drying the conductive ink (e.g., silver) may be selected such that the PU does not soften and also the fabric does not burn.

In some aspects where the flexible substrate layer <NUM> is made of TPU, the thickness of the TPU substrate may vary from <NUM> ~ <NUM> microns. In some aspects, the TPU is a thermoset Polyurethane that is able to withstand drying the conductive ink (Silver) at some temperatures, but the TPU may thermally degrade at some higher temperatures. To laminate the TPU substrate for protection, a similar layer of TPU may be used having a same thickness or being thicker than the substrate to provide the coating layer <NUM>.

In some aspects, the conductive ink used for forming the antenna <NUM> may be a conductive ink including silver nanoparticles in a solvent.

In some aspects, the sensor <NUM> may include a ceramic integrated circuit (IC, as provided by Impinj, NXP, EM, or a custom ASIC). The ceramic IC may include a chip loop antenna made of aluminum etched on PET material may have a pressure-sensitive adhesive such that the chip loop can be coupled to the antenna <NUM> formed on a fabric or TPU substrate.

In one aspect, for example, the sensor tag <NUM> may have small width, e.g., <NUM>, allowing it to be introduced in between a lap seam of a garment such as a t-shirt. The leap weave may be used to seal two pieces of cloth and may be between <NUM> and <NUM>. Accordingly, since the sensor tag <NUM> is integrated into a lap seam, the sensor tag <NUM> does not disturb the design of the garment. In contrast, conventional sensor tags that include copper wires may appear a protrusion and may be felt by a person wearing a garment to which that tag is attached. In some aspects, multiple flexible sensor tags <NUM> conforming to multiple frequency bands (e.g., European Union (EU) bands, North American bands, etc.) may be integrated into such a leap seam.

In one non-limiting example aspect, the flexible substrate layer <NUM> may be a strip of fabric substrate. Also, the coating layer <NUM> may be made of fabric, such as a PU cover with a <NUM> micron thickness, thus providing a fabric-on-fabric sensor tag <NUM>. In this example aspect, the sensor tag <NUM> may be up to <NUM> wide and <NUM> long, with no curvature and no plasticized surface. Accordingly, the fabric-on-fabric sensor tag <NUM> may be supple but still maintain straightness, hence providing improvement over TPU-on-fabric sensor tags <NUM>. Further, the fabric-on-fabric sensor tag <NUM> is more robust and therefore particularly suitable for feeding through fixtures. Additionally, the fabric-on-fabric sensor tag <NUM> maintains straightness thus better maintaining co-planarity and providing more consistent RFID reads. Yet further, the fabric-on-fabric sensor tag <NUM> does not impact the fall of a garment or interfere with design aesthetics. Additionally, the fabric-on-fabric sensor tag <NUM> may be water proof to a certain extent as the fabric is already coated with TPU.

In addition to the aspects disclosed herein, the above-described features, advantages and characteristics of the sensor tag <NUM> may be combined in any suitable manner in one or more additional aspects. One skilled in the relevant art will recognize, in light of the description herein, that the present solution can be practiced without one or more of the specific features or advantages of a particular aspect. In other instances, additional features and advantages may be recognized in certain aspects that may not be present in all aspects of the present solution.

<FIG> is a flow diagram of an example method of configuring a sensor tag according to some present aspects. At <NUM> the method <NUM> includes printing one or more antennas <NUM> on a flexible substrate layer <NUM> using a conductive ink. At <NUM> the method <NUM> includes depositing one or more sensors <NUM> on the flexible substrate layer <NUM>, where at least one of the one or more sensors <NUM> is deposited to make electric contact with at least one of the one or more antennas <NUM>. At <NUM> the method <NUM> includes applying a coating layer <NUM> over the one or more sensors <NUM>.

In an aspect, for example, the coating layer <NUM> may include a colorless or colored TPU layer or a PU fabric layer.

In an aspect, for example, the flexible substrate layer <NUM> may include a TPU layer, a fabric layer, a PU fabric layer, a nylon taffeta layer, a polyester taffeta layer, or a rubber layer.

In an aspect, for example, the flexible substrate layer <NUM> may include a film of TPU over a fabric layer. in this aspect, the printing at <NUM> may include printing on the film of TPU, and the depositing at <NUM> may include depositing on the film of TPU. In an aspect, for example, the applying at <NUM> may include encapsulating the one or more sensors <NUM> between the TPU film and the coating layer <NUM>. In an aspect, for example, the coating layer <NUM> may include TPU, and the applying at <NUM> may further include leaving a TPU-free margin around the flexible substrate layer <NUM>.

In an aspect, for example, the flexible substrate layer <NUM> may include a fabric layer. In this aspect, the applying at <NUM> may include encapsulating the one or more sensors <NUM> and at least a portion of the fabric layer within the coating layer <NUM>. In an aspect, for example, the coating layer <NUM> may include TPU. In this aspect, the applying at <NUM> may further include leaving a TPU-free margin around the fabric layer.

In an aspect, for example, the one or more sensors <NUM> may include an RFID sensor.

In an aspect, for example, the one or more sensors <NUM> may include an EAS sensor.

In an aspect, for example, the one or more sensors <NUM> may include an RFID sensor and an EAS sensor.

In an aspect, for example, the printing at <NUM> may include screen printing, stencil printing, ink jet printing, or coating.

In an aspect, for example, the printing at <NUM> may include printing at least a portion of the one or more antennas <NUM> in a stripe, rectangular, or meandering shape.

In an aspect, for example, the method <NUM> may further include curing the one of more antennas <NUM> subsequent to the printing at <NUM> and prior to the depositing at <NUM>.

In an aspect, for example, the curing may include oven drying or thermally curing.

In an aspect, for example, the applying at <NUM> may include laminating or heat sealing.

In an aspect, for example, the laminating or heat sealing may include using a heat gun.

Claim 1:
A method for configuring a sensor tag (<NUM>), comprising:
- printing one or more antennas (<NUM>) on a flexible substrate layer (<NUM>) using a conductive ink;
- depositing one or more sensors (<NUM>) on the flexible substrate layer (<NUM>), wherein at least one of the one or more sensors (<NUM>) is deposited to make electric contact with at least one of the one or more antennas (<NUM>); and
- applying a coating layer (<NUM>) over the one or more sensors (<NUM>);
- wherein the flexible substrate layer (<NUM>) comprises a film of thermoplastic polyurethane (TPU) over a fabric layer; and
- wherein the printing comprises printing on the film of TPU; and
- wherein the depositing comprises depositing on the film of TPU; and
- wherein the applying comprises encapsulating the one or more sensors (<NUM>) between the TPU film and the coating layer (<NUM>); and
- wherein the coating layer (<NUM>) comprise thermoplastic polyurethane (TPU),
characterised in that
the applying further comprises leaving a TPU-free margin around the flexible substrate layer (<NUM>).