Patent Description:
RFID tags and labels (collectively referred to herein as "devices") are widely used to associate an object with an identification code. RFID devices generally include an antennae and analog and/or digital electronics, which may include, for example, communications electronics, data memory, and control logic. RFID devices can be used for a variety of applications, for example, security locks in cars, access control to buildings, and tracking inventory and parcels.

One difficulty associated with RFID devices is securing the functional components (namely, an RFID chip and associated antenna) or "RFID inlay" to certain materials, such as ultra-soft fabric or very thin materials or exotic/unconventional materials, using conventional techniques. Providing an approach to securing an RFID inlay to such materials would be advantageous, particularly if such an approach also allowed for reduced manufacturing costs and promoted sustainability (i.e., reuse of selected materials used during the manufacturing process).

<CIT> discloses an apparatus for printing and memory tag application onto a base medium is described. The apparatus includes a print head for printing onto the base medium, and a memory tag dispenser movable relative to the base medium for applying memory tags to the base medium. The print head may also be moveable relative to the base medium. A method of printing onto a base medium and applying a memory tag to the base medium is also described. It comprises the steps of: i) feeding the base medium along a first axis past a print head; ii) printing onto the base medium; iii) feeding the base medium past a memory tag dispenser; and iv) moving the memory tag dispenser relative to the base medium and applying a memory tag to the base medium at a desired location.

<CIT> discloses the following features: a method of transferring an RFID inlay (see paragraphs [<NUM>]-[<NUM>] and <FIG> of <CIT>). The method comprising: securing an RFID inlay (memory tag <NUM> in <CIT>) to a first substrate (substrate <NUM> in <CIT>) with a first adhesive (see paragraph [<NUM>] "appropriate adhesive" in <CIT>); bringing the RFID inlay (memory tag <NUM> in <CIT>) into the vicinity of, and securing the RFID inlay to, a second substrate (paper sheet <NUM> in <CIT>) using a second adhesive (paragraph see [<NUM>] "further adhesive" in <CIT>), dissociating the RFID inlay from the first substrate ( see paragraph [<NUM>] in <CIT>: "the empty substrate <NUM>, following the removal of the memory tags <NUM>, is wound onto roller <NUM>").

<CIT> discloses a method of forming an electrically-conductive pattern including selectively electroplating the top portions of a substrate that corresponds to the pattern, and separating the conductive pattern from the substrate. The electroplating may also include electrically connecting the conductive pattern to an electrical component. Conductive ink, such as ink including carbon particles, may be selectively placed on the conductive substrate to facilitate plating of the desired pattern and/or to facilitate separation of the pattern from the substrate. An example of a conductive pattern is an antenna for a radio-frequency identification (RFID) device such as a label or a tag. One example of an electrical component that may be electrically connected to the antenna, is an RFID strap or chip.

<CIT> discloses a device, such as a radio frequency identification (RFID) inlay structure for an RFID tag or label, including a microstructure element, with leads coupling the microstructure element to other electrical or electronic components of the device. The leads may be electroless-plated leads, and may contact connectors of the microstructure element without the need for an intervening planarization layer.

<CIT> discloses a method, system, and apparatus for a die frame, and for transferring integrated circuit dies therewith. In one aspect for making a die frame, a wafer that comprises a plurality of dies is attached to a surface of a tape structure. A grid of grooves is formed in the wafer to separate the plurality of dies on the surface of the tape structure. A portion of the tape structure that is accessible through the grooves of the grid is caused to harden into a grid shaped structure. The grid shaped structure removably holds the plurality of dies. One or more dies of the plurality of dies can be moved from the grid shaped structure onto a target surface. In an alternative aspect, when the grid of grooves is formed in the wafer to separate the plurality of dies on the surface of the tape structure, the surface of the tape structure is breached in the grooves. The breach causes a hardening material encapsulated in the tape structure to be released and to harden in the grooves into a grid shaped hardened material.

<CIT> discloses a method for assembling a device. The method comprises placing a functional element in a first opening formed in a template substrate and transferring the functional element to a device substrate having a second opening formed therein wherein the functional element is held within the second opening and against an adhesive film coupled to the device substrate.

The dependent claims are directed to preferred embodiments.

Methods for transferring an RFID inlay are described herein. In some embodiments, the RFID inlay contains a chip electrically coupled to an antenna. The chip can be electrically coupled to an antenna using techniques known in the art. In some embodiments, the chip is electrically conducted to an antenna using a conductive adhesive. In some embodiments, the chip can be attached using a "direct-attach" process or a "strap attach" process. In some embodiments, the antenna can be formed of materials known in the art. In some embodiments, the antenna is formed from a metal or metallic material, such as aluminum, copper, or nickel. In some embodiments, the metallic material is a metallic foil. In other embodiments, the antenna is formed using a conducting ink.

In some embodiments, the method includes securing an RFID inlay to a first substrate. In some embodiments, the first substrate is a conventional material, for example, polymeric (e.g., PET) materials, cellulose-based materials (e.g., paper), textiles, fabrics, knits, etc. In some embodiments, the inlay can be secured using techniques known in the art. In some embodiments, the inlay is secured to the substrate using an adhesive. In some embodiments, the adhesive is applied in any desired pattern or configuration. In some embodiments, the adhesive is applied in a shape or pattern that is desired for an antenna. In some embodiments, the first adhesive is a conductive adhesive.

In some embodiments, the RFID inlay is then brought into the vicinity of a second substrate and secured to the second substrate with a second adhesive. In some embodiments, the second substrate is a conventional substrate as described above. In other embodiments, the second substrate is an unconventional material, for example, an ultra-soft fabric or very thin material or exotic material In some embodiments, the RFID inlay is then dissociated from the first substrate.

Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriate manner.

<FIG> illustrates an exemplary RFID inlay <NUM> according to the present disclosure. The RFID inlay <NUM> of <FIG> includes an RFID chip <NUM> (which may be variously configured without departing from the scope of the present disclosure) that is electrically coupled to an antenna <NUM> (which also may be variously configured without departing from the scope of the present disclosure). In the illustrated embodiment, the RFID chip <NUM> is coupled to the antenna <NUM> by a conductive adhesive <NUM>, but different means for coupling the RFID chip <NUM> to the antenna <NUM> may be employed without departing from the scope of the present disclosure.

The RFID inlay <NUM> is secured to a conventional substrate <NUM> (e.g., formed of a paper or polyethylene terephthalate material) by an adhesive <NUM>. The manner in which the RFID inlay <NUM> is assembled and secured to the substrate <NUM> may vary without departing from the scope of the present disclosure. In one embodiment, the substrate <NUM> is provided as a web of material that is unwound from a reel. The adhesive <NUM> is applied to the substrate <NUM> as the substrate <NUM> is unwound from the reel or, alternatively, if the adhesive <NUM> is already present on the substrate <NUM>, a liner is removed to expose the adhesive <NUM> as the substrate <NUM> is unwound from the reel. In one embodiment, the adhesive <NUM> is applied in the shape that is desired for an antenna <NUM> of the RFID inlay <NUM>, but the adhesive <NUM> may be otherwise applied or configured without departing from the scope of the present disclosure.

The substrate <NUM> with exposed adhesive <NUM> continues unwinding from the reel, with a conductive material being applied to at least portions of the adhesive <NUM>. The conductive material may be applied according to any suitable approach and in any pattern without departing from the scope of the present disclosure, but according to one exemplary embodiment, a web of conductive material (e.g., an aluminum foil) is provided, with the conductive material being unwound from a reel and brought into contact with the adhesive <NUM>. The conductive material (if not provided in a final configuration) is formed into the shape of an antenna (e.g., using a die- or laser-cutting procedure) and then any excess material is removed by any suitable approach. In one exemplary embodiment, the adhesive <NUM> is provided in the shape that is desired for the antenna <NUM>, in which case the conductive material may be stripped away from the substrate <NUM>, which leaves only the portions of the conductive material in contact with the patterned adhesive <NUM>, as an antenna <NUM>. The substrate <NUM> (with the conductive material in the shape of an antenna <NUM>) is then wound onto a second reel. By employing such a reel-to-reel process, a plurality of antennas <NUM> may be sequentially applied to the substrate <NUM>, allowing for the efficient creation of a plurality of RFID inlays <NUM>.

The substrate <NUM> (with the plurality of antennas <NUM>) is subsequently unwound from the reel and a chip adhesive <NUM> is sequentially applied to each antenna <NUM>. An RFID chip <NUM> is then applied to the chip adhesive <NUM> (using a "direct chip attach" approach or a "strap attach" approach, for example) to electrically couple the RFID chip <NUM> to an associated antenna <NUM>. This may include applying pressure and/or heat to cure the chip adhesive <NUM> and bond the RFID chip <NUM> to the antenna <NUM>, thereby forming an RFID inlay <NUM>. Following formation, each RFID inlay <NUM> may be tested, with the substrate <NUM> (with the plurality of RFID inlays <NUM>) being wound onto another reel. Again, it should be understood that the preceding approach to assembling an RFID inlay <NUM> and securing the RFID inlay <NUM> to an initial substrate <NUM> is merely exemplary and that any other suitable approach may be employed without departing from the scope of the present disclosure.

With the RFID inlay <NUM> secured to the substrate <NUM>, a second substrate <NUM> is secured to the RFID inlay using a second adhesive <NUM>, as in <FIG>. As described above, the first substrate <NUM> is formed of a conventional substrate material. While the second substrate <NUM> may also be formed of a conventional substrate material, it may instead be formed of an unconventional material (e.g., an ultra-soft fabric or very thin material or exotic material) that is not well-suited for conventional approaches to applying an RFID inlay to a substrate (e.g., the above-described approach to applying the RFID inlay <NUM> to the first substrate <NUM>).

When the RFID inlay <NUM> has been secured to the second substrate <NUM>, the first substrate <NUM> is dissociated from the RFID inlay <NUM>, leaving the RFID inlay <NUM> secured only to the second substrate <NUM>, as in <FIG>. Subsequently, an additional or third substrate (e.g., a liner) may be applied to the RFID inlay <NUM>, with the RFID inlay <NUM> positioned between the second substrate <NUM> and the third substrate. The first substrate <NUM> may be dissociated from the RFID inlay <NUM> using any one of a variety of different approaches and systems, with exemplary approaches and systems to be described herein in greater detail.

It should be understood that the assemblies of <FIG> are merely exemplary and that other RFID inlay/first substrate configurations may be employed without departing from the scope of the present disclosure. For example, in an alternative embodiment, an additional layer <NUM> (e.g., a thermal transfer adhesive layer) is provided between the first substrate <NUM> and the first adhesive <NUM> (<FIG>). The assembly of <FIG> may be manufactured according to any suitable approach, including an approach of the type described above. If the above-described approach were employed, an additional step of applying the additional layer <NUM> to the first substrate <NUM> is provided before the first adhesive <NUM> is applied, with the first adhesive <NUM> being applied to the additional layer <NUM>, rather than being applied directly to the first substrate <NUM>. Subsequently, a second substrate <NUM> may be secured to the RFID inlay <NUM> according to any suitable approach (including the above-described approach), resulting in the assembly of <FIG>. Finally, the RFID inlay <NUM> is dissociated from the first substrate <NUM> using a method and/or system according to the present disclosure, resulting in the assembly of <FIG>.

<FIG> and <FIG> illustrate exemplary systems <NUM> and <NUM> for transferring an RFID inlay <NUM> from a first substrate <NUM> to a second substrate <NUM>. It should be understood that the illustrated systems <NUM> and <NUM> and the associated transfer methods are merely exemplary and that differently configured systems and methods may be employed without departing from the scope of the present disclosure.

In the system <NUM> of <FIG>, a first substrate <NUM> having a plurality of RFID inlays <NUM> secured thereto (as in <FIG> or <FIG>, for example) is provided on a reel <NUM>. In the embodiment of <FIG>, the second substrate <NUM> is also provided on a reel <NUM>. Both of the substrates <NUM> and <NUM> are unwound from their respective reels <NUM> and <NUM> by any suitable mechanism (e.g., rollers <NUM> in the illustrated embodiment). If the second substrate <NUM> is provided with a layer of adhesive <NUM> and a liner <NUM>, the liner <NUM> may be unwound from the second substrate <NUM> onto a reel <NUM> to expose the adhesive <NUM>. On the other hand, if the second substrate <NUM> does not include adhesive, an adhesive applicator <NUM> may be provided to apply adhesive <NUM> (e.g., in the form of a spray) to the second substrate <NUM> as the second substrate <NUM> is unwound from the reel <NUM>.

Regardless of how the adhesive <NUM> is applied to the second substrate <NUM>, the RFID inlay <NUM> is brought into the vicinity of the second substrate <NUM>, with the adhesive <NUM> on the second substrate <NUM> facing the RFID inlay <NUM> on the first substrate <NUM>. With the RFID inlay <NUM> in the vicinity of the second substrate <NUM> (as at the location identified in <FIG> at <NUM>), the RFID inlay <NUM> is secured to the second substrate <NUM> using the adhesive <NUM> on the second substrate <NUM>. This results in the configuration shown in <FIG> or <FIG>, for example, with the RFID chip <NUM> in contact with the adhesive <NUM> on the second substrate <NUM>, while the antenna <NUM> is in contact with the adhesive <NUM> on the first substrate <NUM>.

With the RFID inlay <NUM> secured to the second substrate <NUM>, the RFID inlay <NUM> is next dissociated from the first substrate <NUM>. This may include first softening the adhesive <NUM> on the first substrate <NUM> before dissociating the RFID inlay <NUM> and the first substrate <NUM> or instead dissociating the RFID inlay <NUM> from the first substrate <NUM> without first softening the adhesive <NUM> on the first substrate <NUM>. The adhesive <NUM> on the first substrate <NUM> may be softened by any of a number of possible approaches, which depend upon the nature of the adhesive <NUM>. In one embodiment, heat is applied to soften the adhesive <NUM> on the first substrate <NUM> (as indicated at <NUM> in <FIG>). In another embodiment, a softening substance or agent (e.g., a solvent) is applied to soften the adhesive <NUM> on the first substrate <NUM>. Once the adhesive <NUM> on the first substrate <NUM> has been softened, the two substrates <NUM> and <NUM> are moved apart from each other (e.g., by directing the first substrate <NUM> in a direction away from the second substrate <NUM>, as in <FIG>). Moving the substrates <NUM> and <NUM> away from each other results in application of a release force that overcomes the release strength of the softened adhesive <NUM> on the first substrate <NUM> (thereby dissociating the RFID inlay <NUM> from the first substrate <NUM>) without dissociating the RFID inlay <NUM> from the second substrate <NUM>. This results in the configuration shown in <FIG>, for example, with the RFID inlay <NUM> secured only to the second substrate <NUM>.

If the adhesive <NUM> on the first substrate <NUM> is not first softened before dissociating the RFID inlay <NUM> from the first substrate <NUM>, then care must be taken in selecting appropriate adhesives <NUM> and <NUM>. In particular, if the adhesive <NUM> on the first substrate <NUM> is not first softened, its release strength should be less than the release strength of the adhesive <NUM> on the second substrate <NUM>. By such a configuration, moving the substrates <NUM> and <NUM> away from each other (or by moving one of the substrates <NUM>, <NUM> away from the other substrate <NUM>, <NUM>) will apply a release force between the substrates <NUM> and <NUM>. When the release strength of the adhesive <NUM> on the first substrate <NUM> is less than the release strength of the adhesive <NUM> on the second substrate <NUM>, the bond between the RFID inlay <NUM> and the adhesive <NUM> on the first substrate <NUM> will be overcome, thereby dissociating the RFID inlay <NUM> from the first substrate <NUM> without dissociating the RFID inlay <NUM> from the second substrate <NUM>. This results in the configuration shown in <FIG>, for example, with the RFID inlay <NUM> secured only to the second substrate <NUM>. Such an approach to dissociating the RFID inlay <NUM> from the first substrate <NUM> may be referred to as "differential release," because it relies upon a difference between the release strengths of the adhesives <NUM> and <NUM>.

After the RFID inlay <NUM> has been dissociated from the first substrate <NUM>, the first substrate <NUM> may be wound onto a second reel <NUM> for reuse (e.g., for receiving additional RFID inlays and then transferring additional RFID inlays to a different substrate, as described herein). Reusing the first substrate <NUM> rather than disposing of it promotes sustainability while also reducing the costs for manufacturing the RFID devices into which the RFID inlays <NUM> are incorporated (by reducing the material costs).

With the RFID inlay <NUM> secured only to the second substrate <NUM>, the assembly may be subjected to further processing. This may include any additional processing without departing from the scope of the present disclosure. In the embodiment of <FIG>, a third substrate <NUM> (which may be a liner or back face provided as a web of material) is secured to the RFID inlay <NUM> (e.g., using an adhesive), with the RFID inlay <NUM> positioned between the second substrate <NUM> and the third substrate <NUM>. <FIG> also shows (at position <NUM>) the second substrate <NUM> being cut between adjacent RFID inlays <NUM> (e.g., by die-cutting or laser-cutting) to define individual RFID tags or labels. With the third substrate <NUM> still intact, the individual RFID tags or labels may be tested (e.g., as indicated at <NUM> in <FIG>), followed by the third substrate <NUM> being wound onto a finished product reel <NUM>, with the individual RFID tags or labels being ready for removal from the third substrate <NUM> and attachment to or incorporation into an article or piece of merchandise. Alternatively, if the third substrate <NUM> is also cut between adjacent RFID inlays <NUM> to define separate RFID tags or labels, the separate RFID tags or labels may be collected for subsequent attachment to or incorporation into an article or piece of merchandise. Again, it should be understood that the post-dissociation processing steps described above and shown in <FIG> are merely exemplary and that other and/or additional processing steps may be employed without departing from the scope of the present disclosure.

<FIG> shows another exemplary system <NUM> (which may be described as having a "super tight pitch" configuration) that may be employed to transfer an RFID inlay <NUM> from a first substrate <NUM> to a second substrate <NUM>. Similar to the system <NUM> of <FIG>, <FIG> shows a system <NUM> in which both the first substrate <NUM> and the second substrate <NUM> are provided on reels <NUM> and <NUM>, respectively. Both of the substrates <NUM> and <NUM> are unwound from their respective reels <NUM> and <NUM> by any suitable mechanism (e.g., rollers <NUM> in the illustrated embodiment). In the illustrated embodiment, the second substrate <NUM> is provided with a layer of adhesive <NUM> and a liner <NUM>, with the liner <NUM> being unwound from the second substrate <NUM> to expose the adhesive <NUM>. The system <NUM> of <FIG> differs from the system <NUM> of <FIG> because the liner <NUM> is not immediately wound onto a second reel, but rather is directed along a path that departs from the second substrate <NUM> (with the first substrate <NUM> being directed along a path positioned between the diverging paths of the second substrate <NUM> and the liner <NUM>) before being brought back into the vicinity of the second substrate <NUM> for attachment to the RFID inlays <NUM>, as will be described in greater detail herein.

The RFID inlays <NUM> are brought into the vicinity of the second substrate <NUM>, with the adhesive <NUM> on the second substrate <NUM> facing the RFID inlays <NUM> on the first substrate <NUM>. With an RFID inlay <NUM> in the vicinity of the second substrate <NUM> (as at the location identified in <FIG> at <NUM>), the RFID inlay <NUM> is secured to the second substrate <NUM> using the adhesive <NUM> on the second substrate <NUM>. <FIG> shows a tamp <NUM> being employed to move the first substrate <NUM> toward the second substrate <NUM>, but other approaches may be employed without departing from the scope of the present disclosure. Securing an RFID inlay <NUM> to the second substrate <NUM> results in the configuration shown in <FIG> or <FIG>, for example, with the RFID chip <NUM> in contact with the adhesive <NUM> on the second substrate <NUM>, while the antenna <NUM> is in contact with the adhesive <NUM> on the first substrate <NUM>.

With an RFID inlay <NUM> secured to the second substrate <NUM>, the RFID inlay <NUM> is next dissociated from the first substrate <NUM>. This may include first softening the adhesive <NUM> on the first substrate <NUM> before dissociating the RFID inlay <NUM> and the first substrate <NUM> or instead dissociating the RFID inlay <NUM> from the first substrate <NUM> without first softening the adhesive <NUM> on the first substrate <NUM>, as described above in greater detail with regard to the system <NUM> of <FIG>. Regardless of the particular approach employed to dissociate the RFID inlay <NUM> from the first substrate <NUM>, the result is the configuration shown in <FIG>, for example, with the RFID inlay <NUM> secured only to the second substrate <NUM>. After the RFID inlay <NUM> has been dissociated from the first substrate <NUM>, the first substrate <NUM> may be wound onto a second reel <NUM> for reuse, thus promoting sustainability and reducing manufacturing costs.

Claim 1:
A method of transferring an RFID inlay (<NUM>), comprising:
securing an RFID inlay (<NUM>) to a first substrate (<NUM>) with a first adhesive (<NUM>);
providing a second substrate (<NUM>) with a second adhesive (<NUM>) and a liner (<NUM>, <NUM>);
separating the liner (<NUM>, <NUM>) from the second substrate (<NUM>) to expose the second adhesive (<NUM>);
bringing the RFID inlay (<NUM>) into the vicinity of, and securing the RFID inlay (<NUM>) to, the second substrate (<NUM>) using the second adhesive (<NUM>);
dissociating the RFID inlay (<NUM>) from the first substrate (<NUM>); and
securing the liner (<NUM>, <NUM>) to the RFID inlay (<NUM>) after the RFID inlay (<NUM>) is dissociated from the first substrate (<NUM>), to position the RFID inlay (<NUM>) between the second substrate (<NUM>) and the liner (<NUM>, <NUM>).