Patent Description:
Consumer products, such as, but not limited to, garments and textiles, include labels with indicia detailing information such as the garment size, the country of origin, brand information, and instructions on how to care for the product. Manufacturers, or intermediates, purchase labels in bulk for placement on products for easy identification and tracking of products in the marketplace. Labels are generated in batches, or runs, that can include thousands of labels and are often delivered in rolls from which individual labels can be cut and then secured to the products.

Radio Frequency Identification (RFID) tags may be remotely powerable transponders which can be useful for inventory management, supply chain monitoring, security, point of sale processes, and other applications.

<CIT> discloses garment or apparel labels that include RFID devices. More particularly, the garment or apparel tags or labels are enclosed in a flexible bag created by a fluid impervious material that protects the RFID device from maintenance and care treatments as well as garment and apparel processing conditions which may be used to provide certain aesthetic or other characteristics to the apparel item.

<CIT> discloses an anti-theft and/or inventory control device which can be permanently or temporarily installed as an insert within a textile product, such as apparel, footwear, bags accessories, tents, soft goods and others. The device has a sensor which is encapsulated in a waterproof carrier, such as a woven fabric. The fabric with the encapsulated sensor becomes an insert which can be sewn into a garment or product, preferably into a seam or hem. Such installation of the insert into a product can be permanent or temporary.

<CIT> discloses an encapsulated device and method for fabricating a radio frequency identification (RFID) device. The method includes providing a first substrate layer, the first substrate layer including at least one cavity; placing a RFID tag into the cavity; placing a second substrate layer over the first substrate layer, the at least one cavity of the first substrate layer being covered by the second substrate layer; and attaching the second substrate layer to the first substrate layer, the second substrate layer forming a pocket with the first substrate layer.

<CIT> discloses an RFID tag that is formed as part of a printed fabric label (PFL). Generally, foil is adhered to a fabric material with a releasable adhesive, the foil is then cut, such as by a laser to define the antenna pattern and a removable portion. The removable portion is then manually stripped away, and a strap is then attached with adhesive to the antenna. A small square of hot melt over-laminate may be placed over the strap and bonded, and then a top layer of fabric is added and secured with an adhesive from a transfer tape.

<CIT> discloses a tag assembly for attaching an RFID tag including a primary antenna to a flexible surface such as fabric, textile or an item of clothing. The tag assembly has a receptacle including a frame for securely holding the RFID tag, a secondary antenna, and attachment means for attaching the frame to the surface, wherein the frame forms part of the secondary antenna. A method of attaching an RFID tag to a flexible surface is also disclosed.

<CIT> discloses that an RFID webstock containing a relatively high pitch-density array of semiconductive chips is provided and joined to a web bearing relatively widely spaced antennas in a continuous process. The RFID webstock is separated or cut into individual chip sections, with the spacing of the chips being increased as the RFID webstock is die cut. The individual chips on the sections are then joined to corresponding antennas to form an RFID inlay stock. This process is conducive to high speed roll-to-roll production of RFID tag and label roll stock.

Various embodiments will become better understood with regard to the following description, appended claims, and accompanying drawings.

Systems and methods are disclosed herein which describe ultrasonic welded labels including RFID tags. As can be appreciated, it can be advantageous for labels, such as garment and textile care labels, to include RFID tags to improve inventory management, supply chain monitoring, and security. Use of ultrasonic welding can facilitate the formation of labels with improved stiffness and improved durability compared to known labels incorporating RIFD tags. The methods described herein can be particularly useful for roll-to-roll processing.

The systems and methods are described in detail including by reference to <FIG>. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, devices methods, systems, etc. can suitably be made and may be desired for specific applications etc. In this disclosure, any identification of specific techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such.

Generally, the systems and methods described herein detail the formation of RFID-containing labels using ultrasonic welding to bond one or more layers of the label together. Use of ultrasonic welding, as opposed to the use of an adhesive, can facilitate the formation of RFID-containing labels with desirable stiffness, durability, and ease of manufacturing as well as improved design. Ultrasonic welding can facilitate such improvements by offering variable adhesion strength to bonded surfaces in addition to being well suited for roll-to-roll manufacturing.

The labels described herein can generally include any labels with more than one layer, including labels with two or three layers. It is important to note that the present invention is not limited to any number of layers. Labels which can be formed using the techniques described herein can include multilayer printed fabric labels as well as multilayer labels formed of other materials such as wood, paper or carbon fiber which exhibit sufficient flexibility and softness. <FIG> depict multilayer printed fabric labels including layers of printed fabric, an RFID tag, adhesive, and optionally, waterproof layers.

In certain embodiments, the labels can be particularly advantageous for use as a fabric label which can be attached to a garment. As can be appreciated however, the methods described herein can be adapted to alternatively form labels for other applications as well.

Referring now to <FIG>, a first embodiment of a printed fabric label <NUM> with at least one RFID device is presented. The label <NUM> includes a top layer <NUM> and a bottom layer108. In one embodiment contemplated present the top layer <NUM> and the bottom layer <NUM> are both made out of fabric, and in another embodiment presently contemplated both layer <NUM> and <NUM> are printed fabric labels however the present invention is not limited to such. When the label <NUM> is attached to a garment, artwork may be printed on the outward facing sides of the layers <NUM>, <NUM> and may provide consumers with information detailing the garment size, the country of origin, brand information, and instructions on how to best care for the garment. In certain embodiments, the label <NUM> includes at least one printable surface for artwork. The layers <NUM>, <NUM> may be continuous lengths of fabric that have the desired artwork printed periodically along the length of fabric. Generally, the label <NUM> can be formed of any known fabric material and ink as known in the art.

At least one Radio Frequency Identification (RFID) inlay <NUM> is disposed between the top layer <NUM> and the bottom layer <NUM>. If there are a plurality of inlays present, the inlays <NUM> are periodically spaced so as to substantially align with the artwork in the printed fabric layers <NUM>, <NUM>. In certain embodiments, the at least one RFID inlay <NUM> can be carried on a continuous length of substrate that includes RFID devices disposed periodically along the length of the substrate. As would be appreciated in the art, any suitable RFID device known in the art can be used for the RFID inlay <NUM>. For example, an RFID inlay <NUM> can include at least one RFID chip that are each in electrical communication with a suitable RFID antenna of any particular size or shape such as a dipole antenna. The RFID inlay <NUM> can also use RFID straps in electrical communication with corresponding RFID antennas for attachment of the RFID chip to the antenna. In embodiments, multiple RFID inlays <NUM> can be disposed within each individual printed fabric label <NUM>. For example, multiple RFID inlays <NUM> can be used for different applications and each can use a different frequency.

The RFID inlay <NUM> can include an adhesive layer <NUM> configured to secure the RFID inlay <NUM> to the bottom printed fabric layer <NUM>. In certain configurations, the adhesive layer <NUM> can be configured to secure the RFID inlay <NUM> to the top printed fabric layer <NUM>, or, additionally or alternatively, multiple adhesive layers can be used as would be understood in the art. The adhesive layer <NUM> can generally be formed of any known adhesive such as, for example, a pressure-sensitive adhesive ("PSA"), a reactive adhesive, or a hot-melt adhesive. The present invention contemplates that the adhesive layer <NUM> can be pattern or curtain coated. In one embodiment the adhesive layer <NUM> is in the shape of the RFID antenna.

The adhesive layer <NUM> can advantageously prevent the RFID inlay <NUM> from moving once the top layer <NUM> and the bottom layer <NUM> are ultrasonically welded together as discussed in greater detail below. Advantageously, ultrasonically welding the layers <NUM>, <NUM> allows the RFID inlay <NUM> to remain intact even after multiple laundry washing and drying cycles when the RFID tag is attached to an article of clothing. In certain embodiments, the label <NUM> which may also be referred throughout as a printed fabric label <NUM>, can be configured to withstand different environments. For example, the strength and properties of the adhesive can be selected based on a desired chemical, thermal, and ultraviolet resistance profile.

Referring now to <FIG>, a second embodiment of a printed fabric label <NUM> with an RFID device is presented. The printed fabric label <NUM> includes a top printed fabric layer <NUM>, an RFID inlay <NUM>, and a bottom printed fabric layer <NUM> as disclosed above. The printed fabric label <NUM> also includes a waterproofing layer <NUM> configured to act as a water barrier for the RFID inlay <NUM>. In embodiments the waterproofing layer <NUM> can be a film, such as a plastic film, that is applied to the top printed fabric layer <NUM>. In one embodiment, the film is constructed using polyurethane. The waterproofing layer <NUM> can prevent damage to the RFID chip and antenna of the RFID inlay <NUM> when the label <NUM> is in contact with water. In addition to ensuring operation of the RFID inlay <NUM>, the waterproofing layer <NUM> can also prevent possible discoloration of the printed fabric label <NUM> after a user washes a garment that includes a printed fabric label <NUM>. Advantageously, the waterproofing layer <NUM> can allow the RFID chip and antenna of the RFID inlay <NUM> to remain operational even after multiple laundry washing and drying cycles. In certain embodiments, the printed fabric label <NUM> can include an adhesive layer <NUM> as disclosed above. In certain embodiments, the adhesive layer <NUM> can be configured to function as a water barrier for the RFID inlay <NUM> and can obviate the need to include a separate waterproofing layer <NUM>.

In certain embodiments, the RFID inlay <NUM> can be carried on a substrate and the substrate can similarly function as a water barrier. For example, the substrate can include at least two portions that can be folded together about a centerline and welded together. In this example, the substrate can be configured to protect the RFID inlay <NUM> during the welding. The weld can be configured to seal the RFID inlay <NUM>, or a separate material such as an epoxy can be placed over the RFID inlay <NUM> as waterproofing. An example of a suitable material for such substrates is Gore-tex® manufactured by W. Gore and Associates (Newark, DE). As can be appreciated, in other variations, the substrate can include additional fold lines any of which can be folded together and ultrasonically welded.

Advantageously, ultrasonically welding the layers <NUM>, <NUM> can form a waterproof seal around the RFID inlay that prevents water from reaching the RFID inlay <NUM>. In certain embodiments, some or all of the layers can be welded in a configuration that secures the layers together, but which does not surround the RFID inlay <NUM>. In various embodiments, the weld can be made at any suitable place on the printed fabric label <NUM> including at the edges, disposed inward a short distance from the edges, or in any desirable pattern or placement on the printed fabric label <NUM>. In one embodiment, the label is welded around at least four edges. The present invention also contemplates that the label is not welded around its total perimeter but rather only select edges. The welds can be continuous or intermittent.

Referring now to <FIG>, a third embodiment of a printed fabric label <NUM> with an RFID device is presented. The printed fabric label <NUM> includes a top printed fabric layer <NUM>, an RFID inlay <NUM>, and a bottom printed fabric layer <NUM> as disclosed above. The printed fabric label <NUM> includes a first waterproofing layer <NUM> and a second waterproofing layer <NUM>, each of which is configured to act as a water barrier for the RFID inlay <NUM> as describe above. The printed fabric label <NUM> can include an adhesive layer <NUM> as disclosed above. The adhesive layer <NUM> and the substrate of the RFID inlay <NUM> can similarly function as water barriers.

As can be appreciated, the printed fabric layers of <FIG> can be substituted by other known layers such as those formed of plastic, paper, etc. provided they are suitable for the desired end use. For example, softened plastic may be useful for certain garments. Use of such layers may obviate the need to include adhesive and/or waterproofing layers as such materials may inherently provide such functionality.

Generally, ultrasonic welds can be made as known in the art. For example, suitable ultrasonic welding machines to form the ultrasonic welds described herein include those described in <CIT> and <CIT>.

The methods described herein are particularly advantageous for volume production and can be made using, for example, a roll-to-roll processing system.

Referring to <FIG>, a first embodiment of roll-to-roll processing <NUM> is presented. In the roll-to-roll processing <NUM>, a lamination roll <NUM> receives a top printed fabric label layer <NUM>, a substrate with RFID inlays <NUM>, and a bottom printed fabric label layer <NUM>. The lamination roll <NUM> presses together, or joins together, the top printed fabric label layer <NUM>, the substrate with RFID inlays <NUM>, and the bottom printed fabric label layer <NUM> to form a joined label. In certain embodiments, waterproof layers (not shown, see <FIG>) can be disposed between the top printed fabric label layer <NUM> and the RFID inlays <NUM>, and/or the bottom printed fabric label layer <NUM> and the RFID inlays <NUM>. In embodiments the waterproof layers can be pre-applied to the top printed fabric label layer <NUM> and/or the bottom printed fabric label layer <NUM>.

The joined label passes between ultrasonic welders <NUM> and rotary anvils <NUM>. The ultrasonic welders <NUM> weld the top printed fabric label layer <NUM> to the bottom printed fabric label layer <NUM> to form a seal around one of the RFID chips and antennas of the RFID inlay <NUM>. In embodiments, the ultrasonic weld extends through one or more other layers, for example the RFID inlay <NUM> and waterproofing layers if present. The weld can be in any suitable shape, for example a substantially rectangular weld. Any suitable number of ultrasonic welders <NUM> can be utilized. For example, in embodiments a first ultrasonic welder <NUM> seals the edges of the joined label and a second ultrasonic welder <NUM> seals the ends of the joined label. Once sealed, the labels exit the ultrasonic welders <NUM> and rotary anvils <NUM> as a continuous web <NUM>. An edges slitting roller <NUM> trims the edges of the continuous web <NUM> and slit waste <NUM> is discard. The continuous web <NUM> of individually sealed labels can be rolled or otherwise suitably packaged for future use. For example, the continuous web <NUM> can be delivered to a garment manufacturer where individual labels can be cut from the continuous web <NUM> and attached to garments by the garment manufacturer.

Referring now to <FIG> a second embodiment of roll-to-roll processing <NUM> is presented. As describe above, in the roll-to-roll processing <NUM> a top printed fabric label layer <NUM>, a substrate with RFID inlays <NUM>, and a bottom printed fabric label layer <NUM> are pressed and joined together by a lamination roll <NUM>, and welded between ultrasonic welders <NUM> and rotary anvils <NUM>. An edges slitting roller <NUM> trims the edges of the continuous web <NUM> and slit waste <NUM> is discard. The continuous web <NUM> passes between web guides <NUM> and a sonic knife <NUM> cuts the continuous web <NUM> into individual labels <NUM> that each contain an RFID chip and antenna. The individual labels <NUM> are dispensed by the web guides <NUM> after which the individual labels <NUM> can be attached to a garment or packaged together for delivery to a garment manufacturer.

Claim 1:
A label (<NUM>), comprising:
a first printed fabric label layer (<NUM>) and a second printed fabric label layer (<NUM>);
at least one radio frequency identification, RFID, inlay (<NUM>) disposed between the first printed fabric label layer (<NUM>) and the second printed fabric label layer (<NUM>);
a first waterproof layer (<NUM>) disposed between the at least one RFID inlay (<NUM>) and the first printed fabric label layer (<NUM>); and
characterized by the label (<NUM>) further comprising:
a second waterproof layer (<NUM>) disposed between the at least one RFID inlay (<NUM>) and the second printed fabric label layer (<NUM>);
wherein the first printed fabric label layer (<NUM>) is welded to the second printed fabric label layer (<NUM>) by a weld which extends through the first waterproof layer (<NUM>), the RFID inlay (<NUM>), and the second waterproof layer (<NUM>), to form a seal around the RFID inlay (<NUM>).