Flexible smart label with integrated activation mechanism

Abstract

A smart label can include a flexible printed circuit (FPC) configured to support electronic components, including a wireless personal area network (WPAN) circuit with a microcontroller and a radio frequency component. The smart label also can include a battery attached to the FPC and configured to supply power to the WPAN circuit. The smart label also can include a breakable conductive trace electrically connected to an input port of the WPAN circuit. The breakable conductive trace can be configured to sever upon peeling of the smart label from a release liner, wherein severing the breakable conductive trace changes a voltage level at the input port to transition the WPAN circuit from a low-power state to an active state.

Description

Attorney Docket: MX-24467-WO-PCTFLEXIBLE SMART LABEL WITH INTEGRATED ACTIVATION MECHANISMBACKGROUND

[0001] Asset tracking technologies are essential across various industries, including logistics, pharmaceuticals, manufacturing, and cold-chain monitoring. Effective asset tracking requires real-time monitoring, activation, and data transmission to ensure accurate location information, status updates, and condition monitoring. However, traditional asset tracking solutions face several limitations in achieving these objectives efficiently.

[0002] Conventional asset tracking labels generally depend on manual activation methods, such as pressing buttons, pulling tabs, or utilizing field-based technologies like near-field communication (NFC) and radio frequency identification (RFID). While these methods facilitate real-time monitoring, they introduce complexity to deployment, as they necessitate additional components that increase production costs and add bulk to the labels. Furthermore, manual activation methods are impractical in high-volume deployment environments, where rapid and simultaneous activation of multiple labels is required.

[0003] Moreover, the physical nature of manual activation (e.g., pressing a button or pulling a tab) limits the flexibility of the label design. As a result, existing labels may not be easily adaptable to various surface types or constrained spaces, leading to reduced reliability in adherence and activation. Field-based activations, such as NFC or RFID, often require proximity to an activating device, which is not always feasible or efficient, particularly in high- volume or fast-paced environments.

[0004] The absence of a streamlined, integrated activation mechanism within asset tracking labels has restricted the scalability and cost-effectiveness of existing solutions. In many cases, asset tracking becomes inefficient, costly, and labor-intensive due to the need for individual label activation. Additionally, existing methods may struggle to perform reliably in diverse environments, ranging from high-temperature logistics to low- temperature cold-chain monitoring. These challenges underscore a pressing need for an improved solution that simplifies activation, enhances flexibility, and reduces both costs and deployment efforts.SUMMARY

[0005] One general aspect includes a smart label. The smart label includes a flexible printed circuit (FPC) configured to support electronic components, including a wirelessAttorney Docket: MX-24467-WO-PCT personal area network (WPAN) circuit with a microcontroller and a radio frequency component. The radio frequency component can be or can include a radio frequency transmitter or a radio frequency transceiver. The label also includes a battery attached to the FPC and configured to supply power to the WPAN circuit. The label also includes a pressure-sensitive adhesive (PSA) layer positioned beneath the FPC and configured to secure the smart label to a surface. In one or more implementations, the PSA layer also contains a barrier film that, along with the label material, provides environmental encapsulation of the electronic components. The label also includes a breakable conductive trace electrically connected to an input port of the WPAN circuit, the breakable conductive trace configured to sever upon peeling of the smart label from a release liner, wherein severing the breakable conductive trace changes a voltage level at the input port to transition the WPAN circuit from a low-power state to an active beaconing state.

[0006] Implementations may include one or more of the following features . The smart label where the PSA layer includes a pre-cut tear-off tab window aligned with the breakable conductive trace. The smart label may include one or more sensors integrated on the FPC and configured to communicate data to the WPAN circuit. The one or more sensors include a temperature sensor, a humidity sensor, an accelerometer, a gyroscope, a light sensor, a proximity sensor, a pressure sensor, or a gas sensor. The smart label may include programming points positioned on or near an activation tab of the FPC, allowing for initial programming and configuration of the smart label. The WPAN circuit includes a matching network and an antenna configured to facilitate short-range wireless communication. The FPC further may include a ground plane configured to reduce electromagnetic interference and enhance signal integrity. The PSA layer may include an acrylic, rubber-based, or silicone-based adhesive formulated to form and maintain adhesion under varying environmental conditions.

[0007] One general aspect includes a smart label web assembly. The smart label web assembly also includes a release liner. The assembly also includes a plurality of smart labels arranged on the release liner, each smart label of the plurality of smart labels may include: an FPC configured to support electronic components; a battery attached to the FPC; a breakable conductive trace electrically connected to an input port of the electronic components, the breakable conductive trace configured to sever upon peeling from the release liner, wherein severing the breakable conductive trace changes a voltage level at the input port to transition the electronic components from a low-power state to an activeAttorney Docket: MX-24467-WO-PCT state; and a tear-off tape strip aligned with the breakable conductive trace of each smart label of the plurality of smart labels and configured to apply a controlled force to sever the breakable conductive trace upon peeling from the release liner.

[0008] Implementations may include one or more of the following features . The smart label web assembly where each smart label includes a PSA layer with a pre-cut tear-off tab window aligned with the breakable conductive trace. Each smart label further includes one or more sensors in communication with a microcontroller within the FPC. The smart label web assembly may include programming points on each FPC, configured to allow programming of operational parameters for each smart label. The tear-off tape strip is adhered to the release liner and remains on the release liner when the smart label is peeled away. The release liner and the tear-off tape strip are configured to sequentially expose each smart label for deployment and activation. The tear-off tape strip is laminated in register with each pre-cut tear-off tab window to align with an activation tab of each smart label.

[0009] One general aspect includes a method for manufacturing a smart label web assembly. The method also includes forming a tear-off tab window in a PSA layer. The method also includes aligning an FPC and a battery in register with the PSA layer, where the FPC includes a breakable conductive trace. The method also includes laminating a labelstock over the FPC and the PSA layer. The method also includes cutting the labelstock and PSA layer to define individual smart labels on a release liner.

[0010] Implementations may include one or more of the following features. The method may include laminating a tear-off tape strip in register with each pre-cut window to align with the breakable conductive trace on each FPC. The method may include programming each smart label by interfacing with exposed programming points through the pre-cut window. The method may include placing spacers between adjacent FPCs to prevent compression or unintended contact between neighboring components. Cutting may further include defining boundaries of each smart label through the labelstock layer and the PSA layer without penetrating the release liner. The method may include testing each smart label after programming to verify activation functionality and operational parameters.

[0011] One general aspect includes a method for deploying and activating a smart label. The method also includes peeling a tear-off tape strip from a release liner to expose an activation tab aligned with a tear-off tab window of a PSA layer. The method alsoAttorney Docket: MX-24467-WO-PCT includes peeling the smart label from the release liner, thereby severing a breakable conductive trace positioned in alignment with the activation tab, wherein severing the breakable conductive trace changes a voltage level at an input port of the WPAN circuit to transition the WPAN circuit from a low-power state to an active state.

[0012] Implementations may include one or more of the following features. The method may include applying the smart label to an asset surface using the PSA layer. The method may include verifying the activation of the WPAN circuit upon deployment. The method may include monitoring environmental conditions via one or more sensors integrated within the smart label after activation. The method may include configuring the WPAN circuit to enter a low-power mode after initial activation to conserve battery life. The method may include automatically transmitting data from the WPAN circuit to an external device after activation. The method may include securing the smart label in an operational position on a target asset.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0014] FIG. 1A depicts a cross-section view of a smart label web assembly, showing multiple smart labels arranged sequentially on a continuous release liner with a tear-off tape strip for automated activation according to an example implementation.

[0015] FIG. IB depicts a bottom view of the smart label web assembly, illustrating the alignment of the tear-off tape strip with the activation tabs and a pressure-sensitive adhesive (PSA) layer on each smart label according to an example implementation.

[0016] FIG. 2 depicts a flowchart showing a method for manufacturing the smart label web assembly according to an example implementation.

[0017] FIGS. 3A-3G depict a detailed assembly process, including the formation of windows in the PSA layer, alignment of components, placement of spacers, lamination of layers, kiss-cutting for label definition, programming configuration, and tear-off tape strip alignment according to an example implementation.Attorney Docket: MX-24467-WO-PCT

[0018] FIG. 4 depicts a flowchart showing a method for deploying and activating the smart labels after manufacturing according to an example implementation.DETAILED DESCRIPTION

[0019] The challenge of efficiently tracking assets in real-time across various industries, such as logistics, pharmaceuticals, and cold-chain monitoring, is complicated by the limitations of traditional asset tracking labels. These labels typically rely on manual activation methods, such as buttons, pull tabs, or field-based triggers like near field communication (NFC) or radio frequency identification (RFID). Such methods add complexity to deployment, require additional components, increase costs, and create barriers to scalability. Additionally, existing activation mechanisms can be unreliable, cumbersome, or impractical in environments where rapid, high-volume deployment is required. Manual activation increases labor and slows down processes, while field-based activations are often constrained by proximity requirements.

[0020] This disclosure provides a smart label with an integrated, flexible printed circuit (FPC). The FPC serves as the primary substrate, supporting various electronic components while maintaining flexibility. Constructed from materials such as polyimide or polyester film, the FPC enables the smart label to conform to diverse surfaces, making it ideal for application on assets with complex geometries. Embedded conductive traces within the FPC facilitate electrical connectivity between the components, supporting the activation and communication functions of the smart label.

[0021] A wireless personal area network (WPAN) circuit can be attached to the FPC. In one or more implementations, the WPAN circuit is or includes a Bluetooth® low energy (BLE) circuit, a Zigbee® circuit, a Z-Wave® circuit, and / or the like. The WPAN circuit can be attached to the FPC using surface-mount technology (SMT), through-hole technology (THT), or chip-on-board (COB). Using SMT, the WPAN circuit can be attached directly onto a surface of the FPC without the need for through-hole connections. Alternatively, the WPAN circuit can be attached to the FPC using THT where component leads are inserted into holes in the FPC or as a separate semiconductor chip attached directly to the FPC.

[0022] The WPAN circuit will be described herein in one non-limiting example as a BLE circuit. The BLE circuit can include a microcontroller, a radio frequency (RF) component, and supporting components such as antennas, matching networks, and filters. The microcontroller manages data processing and transmission and operates in low-powerAttorney Docket: MX-24467-WO-PCT mode to conserve energy. The RF component operates in the 2.4 GHz industrial, scientific, and medical (ISM) band, enabling short-range wireless communication. A small, integrated battery provides direct current (DC) power to the BLE circuit and supplies energy to both the microcontroller and the RF component. The placement of the battery on the FPC minimizes the overall thickness of the label to maintain a compact form factor. The RF component may include an RF transmitter or an RF transceiver.

[0023] One or more sensors can also be attached to the FPC and can be electrically connected to the circuit via circuit traces (e.g., copper traces). Examples of sensors can include, but are not limited to, thermistors, humidity sensors, accelerometers, gyroscopes, light sensors, proximity sensors, pressure sensors, vibration sensors, gas sensors, and the like. Each sensor can be directly linked to the microcontroller on the BLE circuit to facilitate data collection at specified intervals or based on preset conditions. The microcontroller can digitize and process sensor data received from the sensor(s). The microcontroller can transmit the sensor data through the BLE circuit, such as to one or more external devices. The sensor(s) can be placed to ensure efficient signal routing and to minimize interference, even when the smart label is flexed, bent, or otherwise arranged.

[0024] The smart label can also include an automatic activation mechanism implemented as a breakable conductive trace on the FPC. The breakable conductive trace is electrically connected to an input port of the BLE circuit, enabling the microcontroller to monitor the status of the trace. This trace serves as a physical trigger for activation, and its continuity or breakage is detected by the microcontroller to initiate or control specific operational states within the smart label circuitry, such as powering on communication functions or activating sensors. Until the activation trace is severed, the microcontroller is maintained in a low power state to minimize battery drain during this inactive state, and therefore maximize the functional lifetime after activation. In one or more implementations, the breakable conductive trace is aligned with a pre-cut window in a pressure -sensitive adhesive (PSA) layer of the smart label. The PSA layer is a flexible adhesive coating applied to the bottom of the smart label that enables the smart label to adhere securely to various surfaces upon contact, without the need for heat, water, or other solvents. In one or more implementations, the PSA layer also contains a barrier film that, along with the label material, provides environmental encapsulation of the electronic components. A release liner can cover the PSA layer to protect the PSA layer from unintended adhesion or contamination before the smart label is applied. The release linerAttorney Docket: MX-24467-WO-PCT can also form a continuous substrate (i.e., web assembly) connecting multiple smart labels and allowing continuous processing by the user. The release liner can also be perforated between smart labels to enable labels to be singulated before activation. The release liner is designed to be easily peeled away from the smart label, exposing the PSA layer for secure attachment to the desired surface.

[0025] When the smart label is peeled from the release liner, the breakable trace physically separates, changing a voltage level at an input port of the BLE circuit to transition the circuit from a low-power state to an active state. The breakable trace is designed to separate with a suitable force to ensure reliable activation only upon peeling and preventing accidental activation during handling. For instance, a suitable force for breaking the conductive trace in the automatic activation mechanism could be in the range of 0.5 to 2.0 Newtons (N). This range is typically sufficient to ensure reliable activation during peeling without causing unintentional breakage during handling or transport. Adjustments to this force range can be made based on factors such as the thickness of the FPC, the adhesive strength of the PSA, and the specific use case of the smart label.

[0026] The disclosed smart label provides several advantages over existing solutions. First, the smart label allows for automatic activation, eliminating the need for manual handling or proximity-based triggers. This significantly reduces labor costs and enhances scalability because multiple labels can be deployed and activated simultaneously with minimal effort. Second, the design of the smart label is highly flexible to support different shapes, sizes, and configurations, as well as the integration of one or more sensors. Third, the structure of the label is compact, cost-effective, and capable of maintaining reliable performance across diverse environmental conditions. Fourth, the smart label enables quality control during manufacturing by allowing non-functional or defective labels to be identified and removed from the web assembly without the need to cut and splice the web, with replacement labels added as needed, thereby ensuring only functioning devices are deployed. By offering these advantages, the flexible smart label addresses the limitations of current asset tracking technologies, making the smart label a versatile, efficient, and cost-effective solution for real-time monitoring.

[0027] Turning now to FIG. 1A, shown is a smart label web assembly 100 according to an example implementation. The smart label web assembly 100 includes multiple smart labels 102(l)-102(N) arranged sequentially on a continuous release liner 104 and a tear- off tape strip 106, where N is an integer. The tear-off tape strip 106 runs longitudinallyAttorney Docket: MX-24467-WO-PCT along the smart label web assembly 100 beneath the release liner 104. Alternatively, as opposed to a single strip that spans the length of the smart label web, the tear-off tape strip 106 can be a series of short segments. Although the smart labels 102 are shown as part of the smart label web assembly 100 having N number of smart labels 102 backed by a continuous release liner 104 and tear-off tape strip 106, each smart label 102 may alternatively be arranged on an individual release liner 104 backed by a corresponding tear-off tape strip 106.

[0028] The smart labels 102(l)-102(N) are multilayered, flexible electronic labels designed for real-time monitoring and tracking applications. The smart labels 102(1)- 102(N) each include corresponding layers that maintain a consistent structural composition across the smart label web assembly 100. These layers can be or can include, in one or more implementations, such as in the illustrated example, a labelstock 108(1)- 108(N), including labelstock release liner portions 110(l)-l 10(N), a flexible printed circuit (FPC) 112(1)-112(N), a battery 114(1)-114(N), and a pressure-sensitive adhesive (PSA) layer 116(1)-116(N) with tear-off tab windows 118(1)-118(N). Each component is numbered to correspond with its respective smart label 102(l)-102(N).

[0029] In an alternative implementation, instead of using the labelstock release liner portions 110(1)- 110(N) to create non-adhesive regions, the adhesive layer of the labelstock 108(l)-108(N) can be selectively applied with pre-cut openings or patterns that omit adhesive in predetermined regions. In this implementation, the labelstock adhesive of the labelstock 108(l)-108(N) is applied with openings corresponding to locations where the FPC 112(1)-112(N) and battery 114( 1)- 114(N) are positioned, creating non-adhesive regions without requiring separate release liner pieces. This selective adhesive application achieves the same functional result of creating areas where the labelstock does not adhere to the underlying components, while simplifying the layer structure by eliminating the need for separate release liner portions beneath the electronic components.

[0030] The labelstock 108 is the outermost layer of the smart label 102. The labelstock 108 is designed to provide protection, flexibility, and a surface for displaying information. The labelstock 108 can be made from a durable, flexible material such as polyethylene terephthalate (PET) fdm, polypropylene (PP) fdm, paper, or other similar fdms that offer both mechanical resilience and environmental resistance. The material can be selected for its ability to withstand various conditions, including moisture, temperatureAttorney Docket: MX-24467-WO-PCT fluctuations, and mechanical stress to ensure that the smart label 102 remains intact and legible throughout its lifecycle.

[0031] The labelstock 108 is configured to carry printed information, such as barcodes, QR codes, text, graphics, other identifying details, or any combination thereof. This information can be pre-printed during manufacturing or added later using thermal transfer, direct thermal, inkjet, laser, and / or other printing methods, depending, for example, on the application requirements. The surface of the labelstock 108 can be treated to enhance print adhesion and clarity in order to ensure that the printed information is clear, durable, and resistant to smudging or fading.

[0032] In one or more implementations, the labelstock release liner 110 is removed, allowing the adhesive layer of the labelstock 108 to bond directly to the FPC 112, thereby forming a unified structure that integrates the labelstock 108 with the underlying electronic components on the FPC 112. Alternatively, in one or more other implementations, the FPC 112 is first bonded to the PSA 116. When the labelstock 108 is later applied over this assembly, the labelstock 108 form an additional protective layer, integrating the FPC 112 and PSA 116 to create a multi-layered structure. The flexibility of the labelstock 108 allows the labelstock 108 to conform to curved or irregular surfaces while maintaining adhesion and readability even in challenging environments.

[0033] Additionally, the labelstock 108 contributes to the overall low-profile design of the smart label 102, helping to maintain a thin form factor that supports deployment across a variety of asset types, including containers, packages, and equipment. The material composition and structural properties of the labelstock 108 make the labelstock 108 part of a protective and functional design of the smart label 102 that ensures both physical durability and informational visibility.

[0034] The labelstock release liner 110 is an intermediate layer within the smart label 102, positioned between the labelstock 108 and the FPC 112. The labelstock release liner 110 serves to protect the adhesive side of the labelstock 108 by preventing premature bonding to the FPC 112 during manufacturing, handling, and storage. The labelstock release liner 110 ensures that the adhesive layer of the labelstock 108 remains uncontaminated and ready for secure bonding when the labelstock release liner 110 is removed during the final assembly or deployment of the smart label 102.

[0035] The labelstock release liner 110 can be constructed from a thin, flexible material such as silicone -coated paper, polyethylene-coated paper, or polyester film. TheAttorney Docket: MX-24467-WO-PCT labelstock release liner 110 can provide a smooth, low-tack surface that enables easy peeling without tearing or leaving residue. The material of the labelstock release liner 110 can be chosen for its non-stick properties, which prevent adhesion of the adhesive of the labelstock 108 until intentional removal. Coatings like silicone or other low-surface- energy materials can be applied to reduce friction and allow for controlled separation from the labelstock 108 and to ensure consistent bonding with the FPC 112 upon removal.

[0036] As a barrier layer, the labelstock release liner portions 110(l)-l 10(N) help facilitate the activation function of tear-off activation tabs, described herein, by specifically and selectively preventing the labelstock 108 from bonding to the tear-off activation tabs of the FPC 112, and thereby allowing the tear-off activation tabs to remain attached to the tear-off tape strip 106 when the smart label 102 is peeled from the release liner 104.

[0037] The thickness of the labelstock release liner 110 can be minimized to contribute to the overall low profde of the smart label 102 while still providing sufficient strength to maintain its form during handling and peeling. The labelstock release liner 110 can be designed to peel away cleanly and completely, leaving no or minimal adhesive residue on the FPC 112 or other components. The properties of the labelstock release liner 110 can be optimized to facilitate high-speed manufacturing processes, where automated peeling and assembly are required, thereby supporting the scalability of smart label production.

[0038] The FPC 112 is the central platform of the smart label 102 and is designed to integrate and support various electronic components, including communication modules, sensors, and power sources. The FPC 112 can be constructed from a thin, flexible substrate, such as polyimide fdm or polyester film. The FPC 112 provides both electrical connectivity and mechanical support while maintaining a low-profile and flexible design. The flexibility of the FPC 112 allows the smart label 102 to conform to various surfaces, such as flat, curved, or irregular surface, making the FPC 112 versatile for applications across diverse asset types.

[0039] Embedded within the FPC 112 are conductive traces, typically made of copper and / or other conductive material(s), that form the electrical pathways connecting the different electronic components. These traces are etched or printed onto the substrate using standard manufacturing techniques such as additive printing, subtractive etching, or semiadditive processes. The traces enable electrical signals and power to flow betweenAttorney Docket: MX-24467-WO-PCT electrical components, such as a WPAN circuit (e.g., BLE circuit), one or more sensors, and the battery 114. In this manner, the FPC 112 ensures seamless communication and functionality within the smart label 102. The layout of the conductive traces can be optimized for efficient signal routing while minimizing potential interference, even when the FPC 112 is flexed or bent. The FPC 112 can be designed to accommodate various mounting methods, such as surface-mount technology (SMT), through-hole technology (THT), or chip-on-board (COB) techniques, allowing for compact integration of the WPAN circuit and other components.

[0040] The battery 114 can also be attached to the FPC 112. The battery 114 supplies direct current (DC) power to the BLE circuit and any onboard sensors. The battery 114 can be securely attached to the FPC 112 to ensure consistent electrical contact and energy flow. The placement of the battery 114 can be optimized to maintain the overall low thickness of the smart label 102 to maintain the design compact and to minimize the overall form factor of the smart label 102.

[0041] The PSA layer 116 is designed to provide a strong and flexible bond that enables the smart label 102 to adhere securely to various surfaces. The PSA layer 116 is positioned beneath the FPC 112 and forms the lowermost adhesive layer of the smart label 102. The PSA layer 116 is engineered to form and maintain reliable adhesion to a variety of surfaces, including metal, plastic, glass, cardboard, and other common materials.

[0042] The PSA layer 116 can be made from a pressure-sensitive adhesive material composed of acrylic, rubber-based, silicone-based compounds, and / or the like. In one or more implementations, the PSA layer 116 is a double-coated tape that contains an adhesive layer on both sides of a PET carrier film. The PET carrier film provides environment barrier properties. These adhesive formulations are selected for their ability to provide a strong initial bond upon contact, without requiring additional heat, water, or solvents for activation. The material of the PSA layer 116 is formulated to ensure that the adhesive maintains its integrity under different environmental conditions, such as varying temperatures, humidity levels, and mechanical stress. This ensures that the smart label 102 remains securely attached to its target surface throughout its intended lifespan, even when subjected to environmental challenges like moisture or temperature fluctuations.

[0043] The thickness of the PSA layer 116 can be optimized to maintain the low- profile nature of the smart label 102, keeping the overall form factor thin while providing sufficient adhesion strength. The adhesive can be evenly coated across the surface of theAttorney Docket: MX-24467-WO-PCTFPC 112 to achieve consistent bonding. The PSA layer 116 is designed to ensure that the smart label 102 can be flexed, bent, or conformed to curved surfaces without compromising the adhesion or functionality of the electronic components within the smart label 102. Additionally, the PSA layer 116 can be manufactured to facilitate easy removal from the release liner 104 during deployment, allowing the smart label 102 to adhere to the intended surface with minimal effort.

[0044] Integrated within the PSA layer 116 is the tear-off tab window 118. The tear- off tab window 118 is a strategically positioned opening that plays a key role in the activation of the smart label 102. The tear-off tab window 118 is an aperture that aligns with a breakable conductive trace 136, described herein, on the integrated activation tab of FPC 112 to ensure that the activation mechanism is exposed to the tear-off tape strip 106 positioned below the release liner 104. The tear-off tab window 118 is precisely cut into the PSA layer 116 during manufacturing to maintain alignment with the activation tab on the FPC 112. This alignment ensures the successful activation of the smart label 102, as it ensures that the tear-off tape strip 106 can apply the necessary force to the breakable conductive trace when the smart label 102 is peeled from the release liner 104.

[0045] The tear-off tab window 118 facilitates automatic activation by allowing the tear-off tape strip 106 to exert a controlled force on the breakable conductive trace of the FPC 112. As the smart label 102 is peeled from the release liner 104 during application, the tear-off tape strip 106 remains adhered to the release liner 104 and engages the exposed activation tab within the tear-off tab window 118. This force breaks the conductive trace of the activation pathway, and the microcontroller 122 will detect the voltage level change, thereby activating a WPAN circuit 120 within the smart label 102. The design of the tear- off tab window 118 is optimized to ensure that activation occurs reliably and consistently during deployment, preventing accidental activation during handling while enabling seamless, hands-free initiation of the electronic components following removal from the release liner 104.

[0046] The FPC 112 can support various components, including the WPAN circuit 120, which can include a microcontroller 122, a radio frequency (RF) component 124, and supporting elements like an antenna 126, a matching network 128, a filter 130, and one or more input and / or output ports (“I / O ports”) 131. The microcontroller 122 is the central processing unit of the FPC 112 and is responsible for managing data processing, sensor integration, communication, and power regulation. The microcontroller 122 can beAttorney Docket: MX-24467-WO-PCT programmed to execute various tasks, such as processing sensor inputs, controlling the activation mechanism, and managing wireless communication via the WPAN circuit 120. The microcontroller 122 is designed to operate in low-power modes to conserve energy and extend the life of the battery 114. The microcontroller 122 can include memory modules for data storage and processing, timers, input / output (I / O) interfaces, and communication ports to connect with other components of the FPC 112.

[0047] The RF component 124 is responsible for enabling short-range wireless communication. The RF component 124 can operate in the 2.4 gigahertz (GHz) industrial, scientific, and medical (ISM) band, supporting protocols like BLE, Zigbee®, or similar wireless technologies. The RF component 124 includes both a transmitter and a receiver to facilitate two-way communication, such as with smartphones, gateways, access points, and / or other WPAN-enabled devices. The RF component 124 converts the processed digital signals from the microcontroller 122 into radio frequency signals for transmission and vice versa. The RF component 124 is designed to minimize power consumption while maintaining effective communication ranges suitable for asset tracking and real-time monitoring.

[0048] The antenna 126 is a conductive element designed to transmit and receive RF signals generated by the RF component 124. The antenna 126 can be patterned directly onto the substrate of the FPC 112 to maintain a low-profile design. The antenna 126 can also be a discrete component (i.e., chip antenna) that is attached to the FPC 112. The antenna 126 can be optimized for efficient propagation of short-range signals (e.g., BLE) to minimize interference and to maximize communication range.

[0049] The matching network 128 interfaces between the RF component 124 and the antenna 126. The matching network 128 can include passive components like capacitors, inductors, and resistors, arranged to match the impedance of the output of the RF component 124 to the input of the antenna 126. This impedance matching ensures that RF power is effectively transmitted or received to reduce signal loss and to enhance overall communication efficiency.

[0050] The filter 130 is a passive component integrated into the WPAN circuit 120 to ensure signal integrity. The filter 130 removes unwanted frequencies from the RF signal path to prevent interference and to allow a desired frequency range to pass through. The filter 130 can include one or more low-pass filters, one or more high-pass filters, one orAttorney Docket: MX-24467-WO-PCT more band-pass filters, or a combination thereof of two or more filters depending on the communication requirements.

[0051] Although the FPC 112 is described in one example implementation as having short-range communication capabilities via the WPAN circuit 120, the WPAN circuit 120 can be replaced or supplemented with mid to long-range RF technologies to extend the communication range of the smart label 102. For instance, the circuit may include a Long Range (LoRa) module, a cellular Internet of Things (loT) module such as Long-Term Evolution for Machines (LTE-M) orNarrowBand-IoT (NB-IoT), or a proprietary sub-GHz RF system. These technologies enable the smart label 102 to communicate over distances ranging from hundreds of meters to several kilometers, making them suitable for applications such as wide-area asset tracking, remote environmental monitoring, and industrial loT deployments. The RF component 124 in such systems would be configured to operate within the respective frequency bands (e.g., 433 MHz, 868 MHz, or 915 MHz for LoRa; or cellular bands for LTE-M and NB-IoT) and could incorporate power-efficient protocols to optimize battery life. The microcontroller 122 can interface with these modules to handle data transmission, protocol management, and communication security.

[0052] The FPC 112 can also include a battery management circuit 132, one or more sensors 134, a breakable conductive trace 136, programming points 138, a ground plane 140, and an activation tab 142. The battery management circuit 132 can regulate the power supply from the battery 114 to the various electronic components on the FPC 112. The battery management circuit 132 can include voltage regulation, power distribution, and protection circuits to ensure stable and efficient power delivery. The battery management circuit 132 may also include a charging controller if the battery 114 is rechargeable, as well as safety features such as overcharge protection, under-voltage lockout, and thermal management to prevent overheating. The battery management circuit 132 can optimize power usage to extend the operational life of the smart label 102.

[0053] The sensor(s) 134 can be integrated into the FPC 112 to monitor various environmental parameters or conditions related to the asset being tracked. The sensor(s) 134 can include temperature sensors, humidity sensors, accelerometers, gyroscopes, or combinations thereof, depending on the application of the smart label 102. Each sensor 134 can be connected to the microcontroller 122 via conductive traces, allowing the microcontroller 122 to collect and process sensor data in real-time. The sensor(s) 134 canAtorney Docket: MX-24467-WO-PCT be surface-atached on the FPC 112 to maintain a compact design and to ensure reliable signal routing.

[0054] The FPC 112 can incorporate an activation mechanism in the form of the breakable conductive trace 136. The breakable conductive trace 136 is electrically connected to an input port of the I / O ports 131 of the WPAN circuit 120, enabling the microcontroller 122 to monitor the status of the trace. The breakable conductive trace 136 serves as a physical trigger for activation, and its continuity or breakage is detected by the microcontroller 122 to initiate or control specific operational states within the smart label circuitry, such as powering on communication functions (e.g., the RF component 124) or activating sensors (e.g., the sensor(s) 134). The breakable conductive trace 136 aligns with the tear-off tab window 118 in the PSA layer 116. The breakable conductive trace 136 also aligns with the labelstock release liner portion 110 that is cut and left atached to the labelstock 108. The labelstock release liner portion 110 prevents the labelstock 108 from adhering to the tear-off activation tab and allows the tear-off activation tab to be removed. This feature ensures reliable activation upon deployment and allows for automatic activation of the smart label 102.

[0055] The programming points 138 are contact points on the FPC 112 that facilitate initial programming, testing, and diagnostics during manufacturing. The programming points 138 can be exposed through a window in the PSA layer 116 to allow connection with external programming tools. The programming points 138 provide a direct interface to the microcontroller 122, enabling software uploads, firmware updates, and functional testing before the smart label 102 is deployed. The programming points 138 are designed for temporary contact and may be disabled for normal operation of the smart label 102 through removal of the tear-off activation tab.

[0056] The programming points 138 can be programmed using one or more external programming tools. For example, an in-circuit serial programmer (ICSP) device can be connected directly to the programming points 138 to upload firmware, conduct diagnostics, and / or perform system tests. The ICSP device can enable developers to load the initial software onto the microcontroller 122 of the WPAN circuit 120, such as to set communication protocols, sensor configurations, and / or activation parameters. A universal serial bus (USB) debugger is another example external programming tool. The USB debugger can be used to interface with the programming points 138, allowing for real-time debugging, code execution tracking, and memory analysis. The USB debugger can be usedAttomey Docket: MX-24467-WO-PCT during the development phase to ensure proper functionality of the WPAN circuit 120, the sensor(s) 134, and / or other components on the FPC 112. As another example, a joint test action group (JTAG) programmer can be connected to the programming points 138 for detailed system analysis, hardware debugging, and firmware updates. The JTAG programmer can be used for testing the microcontroller 122, the RF component 124, and related circuits, ensuring proper operation before the smart label 102 is deployed.

[0057] The ground plane 140 is a conductive layer integrated into the FPC 112 to provide a reference point for the electrical components and reduce electromagnetic interference (EMI). The ground plane 140 helps maintain signal integrity, stabilizes the operation of the RF component 124 and the sensors 134, and enhances the overall performance of the smart label 102. The ground plane 140 can be made of copper or and / or other conductive materials and can extend across the FPC 112 to provide uniform grounding and shielding for sensitive components. In addition, the ground plane 140 can contribute to the structural stability of the FPC 112.

[0058] Turning to FIG. IB, shown is a bottom view of the smart label web assembly 100 according to an example implementation. The smart label web assembly 100 shows an example arrangement of the smart labels 102( 1)- 102(N), the release liner 104, the tear- off tape strip 106, and activation tabs 142(1)-142(N) of the FPCs 112(1)- 112(N). This view emphasizes the configuration of the activation mechanism and adhesive structure as seen from the underside of the smart label web assembly 100.

[0059] The release liner 104 is depicted as the continuous layer supporting the smart labels 102(1)- 102(N) along the entire length of the smart label web assembly 100. Each smart label 102 is outlined by dashed lines, representing the perimeter of the PSA layer 116 and indicating the boundaries of each individual label. The release liner 104 serves as the protective backing for the PSA layer 116 and provides a temporary adhesive barrier until the smart labels 102 are peeled off during deployment.

[0060] The tear-off tape strip 106 runs longitudinally along the smart label web assembly 100 beneath the release liner 104. Alternatively, as opposed to a single strip that spans the length of the smart label web assembly 100, the tear-off tape strip 106 can be a series of short segments, wherein each segment aligns with a tear-off tab window 118. Although the smart labels 102 are shown as part of the smart label web assembly 100 having N number of smart labels 102 backed by a continuous release liner 104 and tear-Attorney Docket: MX-24467-WO-PCT off tape strip 106, each smart label 102 may alternatively be arranged on an individual release liner 104 backed by a corresponding tear-off tape strip 106.

[0061] The tear-off tape strip 106 is positioned to align with the activation tabs 142(1)- 142(N) of the FPCs 112(1)-112(N) in each of the smart labels 102(1)- 102(N). The tear-off tape strip 106 is laminated to the release liner 104 and remains adhered to the release liner 104 when the smart label 102 is peeled away. The tear-off tape strip 106 is designed to apply the necessary force to engage the activation tabs 142, breaking the breakable conductive trace 136 to change a voltage level at an input port of the I / O ports 131 of the WPAN circuit 120, thereby transitioning the WPAN circuit 120 from a low- power state to an active state.

[0062] The activation tabs 142 are visible through the tear-off tab windows 118, which are not shown in this bottom view but positioned above the activation tabs on the FPCs 112. The activation tabs 142 are part of the activation mechanism on the underside of the FPCs 112 and are aligned to interface with the tear-off tape strip 106 during the peeling process. The interaction between the tear-off tape strip 106 and the activation tabs 142 ensures consistent activation of the WPAN circuit 120 across all smart labels 102 in the smart label web assembly 100.

[0063]

[0064] In this bottom view, the activation tabs 142(1)-142(N) of the FPCs 112(1)- 112(N) are visible in alignment with the tear-off tape strip 106. The tear-off tape strip 106 is adhered to the release liner 104 and positioned to adhere to the activation tabs 142 in regions corresponding to the tear-off tab windows 118(1)-118(N) in the PSA layer 116 (positioned above and not visible in this bottom view). The activation tabs 142 are breakaway portions of the FPCs 112. During deployment, when the smart label 102 is peeled from the release liner 104, the tear-off tape strip 106 remains adhered to the release liner 104 and retains the activation tabs 142, pulling them away from the main body of the FPCs 112 and severing the breakable conductive traces 136, a portion of which is on the activation tabs 142. This mechanical separation activates each smart label 102 by changing the voltage level at an input port of the WPAN circuit 120, transitioning the circuit from a low-power state to an active state. Turning now to FIG. 2, shown is a method 200 for manufacturing a smart label web assembly 100 according to an example implementation. This process involves sequential operations to create smart labels 102(l)-102(N) on a continuous release liner 104, each integrated with an activation mechanism via a tear-offAttorney Docket: MX-24467-WO-PCT tape strip 106. While the operations are described in a particular sequence for clarity, it should be understood that these operation may be performed in an alternative order, omitted, or combined as needed for various manufacturing setups. The method 200 can be applied to either an individual smart label or a series of smart labels on a continuous web, with FIGS. 3A-3G illustrating corresponding operations in the process.

[0065] At block 202, windows are pre-cut in a mounting adhesive layer as part of the manufacturing process for the smart labels 102. This step is depicted in FIG. 3A at 300A, which illustrates the process of creating the tear-off tab windows 118 in the PSA layer 116 to align with the activation tabs 142 on the FPCs 112 and other elements of the smart labels 102.

[0066] The pre-cutting process involves aligning two release liners, shown as release linen 104(1) and release linen 104(2), with the PSA layer 116 in between. The PSA layer 116 is the adhesive layer designed to bond the smart label 102 to various surfaces. As shown in FIG. 3A, the tear-off tab windows 118(1)-118(N) are formed by cutting through the release linen 104(2) and the PSA layer 116, but not through release linen 104(1). For example, the tear-off tab windows 118(1)- 118(N) can be formed by cutting through the release linen 104(2) and the PSA layer 116, but not through release linen 104(1) using a kiss-cutting process. The kiss-cutting process exposes the activation tabs 142(1)-142(N) of the FPCs 112(1)-112(N), enabling later activation of the smart label 102 when peeled from the release liner 104 (shown as release linen 104(2) in FIG. 3A).

[0067] The kiss-cutting process is a cutting technique where the top layers of a material, such as a labelstock or adhesive layer, are precisely cut without cutting through the underlying layers or backing material. In this process, a blade or cutting tool is adjusted to penetrate only partially through the material, leaving the bottom layer intact. For example, in the context of the smart label manufacturing step described with respect to block 202, the kiss-cutting process is used to cut through the PSA layer 116 and the release linen 104(2) to form the tear-off tab windows 118(1)-118(N), while keeping the release linen 104(1) intact. The kiss-cutting process allows for easy peeling of the desired layers without damaging the base release liner, facilitating controlled removal and application during the manufacturing and deployment of labels.

[0068] Once the tear-off tab windows 118(1)-118(N) are formed, the release linen 104(1) and waste 302 (including the cut portions of the PSA layer 116 and the release linen 104(2)) are removed to expose specific areas of the PSA layer 116, while maintainingAttorney Docket: MX-24467-WO-PCT the integrity of the release linen 104(2). This controlled removal ensures that only the necessary areas of adhesive are exposed, preventing contamination and misalignment during the subsequent assembly steps.

[0069] At block 204, the FPCs 112(1)- 112(N) and the batteries 114(1)- 114(N) are assembled and placed in register with the PSA layer 116 to ensure precise alignment of the FPCs 112(1)- 112(N) and the batteries 114(1)-114(N) with the tear-off tab windows 118(1)-118(N) in the PSA layer 116. This step aligns the FPCs 112(1)- 112(N), the activation tabs 142(1)- 142(N), and the batteries 114(1)- 114(N) relative to the PSA layer 116 and the release liner 104. As depicted in FIG. 3B at 300B, the FPCs 112(1)-112(N) and the batteries 114( 1)- 114(N) are arranged so that each of the activation tabs 142(1)- 142(N) is aligned with a corresponding one of the tear-off tab windows 118( 1)- 118(N).

[0070] The arrangement shown at 300B ensures that each FPC 112 and battery 114 is positioned accurately to interact with the subsequent components in the assembly process, particularly in relation to the PSA layer 116 and the release liner 104. The alignment guarantees that each activation tab 142 is situated directly over one of the tear-off tab windows 118, allowing for the correct engagement with the tear-off tape strip 106 during the activation step of the smart label 102. In this manner, the structural integrity of the FPCs 112 can be maintained, securing consistent contact between the components, and ensuring reliable activation of the smart label 102 upon deployment.

[0071] At block 206, an optional step involves cutting one or more spacers 304 from spacer material and positioning them in alignment with each FPC 112 and battery 114 in the smart label web assembly 100, situated above the PSA layer 116. This process is depicted generally at 300C in FIG. 3C, which illustrates the strategic placement of the spacers 304 alongside each FPC 112 and battery 114 assembly. The spacers 304 can be made from any suitable material, such as thin, non-conductive materials like PET, polycarbonate, or foam.

[0072] Also at block 206, an optional step involves laminating the spacers 304 in precise alignment with the FPC 112 and battery 114 assemblies within the smart label structure. This lamination step adds a layer of structural integrity to the overall assembly, helping to secure and protect the electronic components. By placing the spacers 304 directly adjacent to FPC 112 and battery 114 assemblies, the spacers 304 create a physical buffer that prevents the components from shifting or coming into unintended contact with each other or with other layers during subsequent processing steps. Laminating the spacersAttorney Docket: MX-24467-WO-PCT304 in this manner provides additional mechanical stability to the assembly, ensuring that the alignment of the FPC 112, the battery 114, and other components remains consistent throughout handling, transport, and final application of the smart label 102. This step also mitigates risks of compression or damage to the FPC 112 and the battery 114, as the spacers 304 absorb and distribute any applied pressure, contributing to the overall durability and reliability of the smart label 102. A function of the spacers 304 is to planarize the top surface of the smart label 102 so that more of the surface of the smart label 102 can be printed on.

[0073] At block 208, the labelstock 108 is laminated over the multilayer structure, which includes the FPCs 112, the batteries 114, the PSA layer 116 and the release liner 104, as depicted generally at 300D in FIG. 3D. This process ensures that the labelstock 108 aligns precisely with the underlying assembly components, encapsulating them for added structural integrity. During this step, a kiss-cutting process is applied to the labelstock release liner 110 at specific positions, identified as kiss cuts 306, which partially cut through the labelstock release liner 110 without penetrating the underlying labelstock 108. The kiss cuts 306 allow selective removal of specific sections ofthe labelstock release liner 110 to expose targeted areas while leaving other portions intact.

[0074] Following the kiss-cutting, the unwanted sections of the labelstock release liner 110 are peeled away, resulting in labelstock release liner waste 308. This removal step leaves designated portions of the labelstock release liner 110 (shown as labelstock release liner portions 110(l)-l 10(N)) aligned over corresponding activation tabs 142(1)- 142(N) and tear-off tab windows 118(1)- 118(N) in the PSA layer 116. By selectively exposing these areas, this step prepares the assembly for later interactions during the activation of each smart label 102. The labelstock 108 now adheres firmly to the assembly beneath, encapsulating the FPCs 112 and the batteries 114 while ensuring the tear-off tab windows 118 remain accessible through the exposed sections created by the kiss cuts 306 and not adhered to the labelstock 108. This structured alignment and controlled exposure maintain the integrity of the smart labels 102, facilitating subsequent processing and ensuring consistent functionality across each smart label 102.

[0075] At block 210, the perimeter of each smart label 102 is kiss cut through the labelstock 108 and the PSA layer 116, without cutting through the underlying release liner 104. As shown in FIG. 3E at 300E, this kiss-cutting process precisely defines the boundaryAttorney Docket: MX-24467-WO-PCT of each smart label 102(l)-102(N) within the continuous structure, allowing the smart labels 102 to remain attached to the release liner 104 for easy handling and transport.

[0076] The kiss cuts 306 extend through both the labelstock 108 and the PSA layer 116 but stop short of penetrating the release liner 104, preserving its structural integrity. Following the kiss-cutting operation, excess material including both labelstock waste 310 and PSA layer waste 312 is removed. This removal of waste material sharpens the delineation of each individual smart label, leaving a clean, precise edge around each smart label 102 on the release liner 104.

[0077] The activation tabs 142(1)-142(N) are positioned within the perimeter of a corresponding one of the smart label 102(l)-102(N) and are aligned with the corresponding tear-off tab windows 118(1)-118(N) in the PSA layer 116 and the release liner 104. This alignment facilitates subsequent activation steps by ensuring that each activation tab 142 remains accessible. After the waste material is removed, each smart label 102 is fully defined within the release liner 104, remaining intact and aligned for further processing or individual deployment as needed.

[0078] At block 212, the smart labels 102 are programmed by interfacing with designated programming points 138, which are exposed through the tear-off tab windows 118(1)-118(N) in the PSA layer 116 and the release liner 104. FIG. 3F illustrates this configuration generally at 3 OOF, where each smart label 102, positioned on the release liner 104, has specific programming points 138 accessible for programming and configuration.

[0079] The programming points 138 serve as direct electrical contacts for programming data into each smart label 102. These points can be strategically located on or near the activation tabs 142 of the FPCs 112. The placement of the programming points 138 enables straightforward alignment with external programming tools, allowing for efficient data input and configuration. Through the programming points 138, various operational parameters can be configured, such as communication protocols, sensor settings, power management features, and device ID’s, tailored for each individual smart label 102.

[0080] The programming points 138 can be visible through precisely cut openings in the PSA layer 116 and the release liner 104. By exposing the programming points 138, manufacturing efficiency can be enhanced by enabling rapid, non-intrusive programming of multiple smart labels simultaneously, all while maintaining the integrity of theAttorney Docket: MX-24467-WO-PCT underlying layers and the alignment of each smart label 102 on the continuous release liner 104. Leaving the programming points exposed until the end of the process allows for custom configurations to be more rapidly deployed, compared to a more traditional method of using pre-programmed microcontroller boards. Another feature of leaving the programming points 138 exposed until the end of the process is that it allows specific information (e.g., firmware configuration, device ID) to be read from the microcontroller, and then printed onto the smart label 102 for identification, without the need to trigger the activation mechanism.

[0081] At block 214, the tear-off tape strip 106 is laminated in precise alignment, with the tear-off tab windows 118(1)- 118(N) in the PSA layer 116 and the release liner 104. FIG. 3G illustrates this configuration generally at 300G, showing the positioning of the tear-off tape strip 106 in the smart label web assembly 100. The tear-off tape strip 106 is applied to span across each smart labels 102 within the smart label web assembly 100, aligning with the programming points 138 and the activation tabs 142 to facilitate easy removal during deployment or activation.

[0082] In an alternative implementation, the assembly sequence can be modified such that the FPCs 112(1)-112(N) and the batteries 114(1)-114(N) are first mounted to the labelstock 108 rather than to the PSA layer 116. In this implementation, the labelstock 108 (with or without the labelstock release liner portions 110( 1 )- 110(N) already positioned) is provided as a base layer, and the FPCs 112(1)-112(N) and the batteries 114(1)-114(N) are placed in register with the labelstock 108. The tear-off tab windows 118(1)- 118(N) are then pre-cut in the PSA layer 116 and the release liner 104 as previously described, and this PSA / release liner assembly is laminated to the underside of the labelstock 108 with the FPC / battery assemblies already in place. This alternative sequence achieves the same structural result while accommodating different manufacturing equipment configurations.

[0083] In FIG. 3G, the tear-off tape strip 106 is adhered to the release liner 104 and aligned over the programming points 138 on each smart label 102. This alignment ensures that the programming points 138 are covered securely while allowing straightforward access upon peeling the tear-off tape strip 106. The tear-off tape strip 106 is also securely adhered to the activation tab 142, ensuring that the activation tab 142 remains with the release liner 104 when the smart label is removed. The programming points 138, positioned on or near the activation tabs 142, serve as interfaces for programming eachAttorney Docket: MX-24467-WO-PCT smart label 102. By laminating the tear-off tape strip 106 in register with these components, block 214 facilitates precise alignment and structural integrity.

[0084] Turning now to FIG. 4, shown is a method 400 for deploying and activating the smart labels 102 according to an example implementation. The method 400 leverages the breakable conductive traces 136 implemented as part of the FPCs 112 as a reliable activation mechanism.

[0085] At block 402, the smart label web assembly 100, including multiple smart labels 102(l)-102(N) arranged sequentially on a continuous release liner 104, is transported to an application station where individual smart labels 102 can be prepared for deployment. Each smart label 102 can remain affixed to the release liner 104, with the tear-off tape strip 106 and the labelstock 108 covering and protecting the underlying electronic components, including the activation tab 142 and the breakable conductive trace 136 integrated within the FPC 112. This configuration ensures that each smart label 102 remains inactive and protected from environmental factors or accidental handling that could otherwise trigger premature activation.

[0086] At block 404, printing can be performed on the labelstock 108. This optional printing may occur at different stages, such as prior to activation, during programming of the smart label 102, or after the smart label 102 is fully assembled. This flexibility in the printing step allows customization of the label to include barcodes, QR codes, graphics, text, or other identifying information, depending on application requirements. The printing may be achieved using various techniques, such as thermal transfer, inkjet, laser, or other suitable methods, ensuring clear and durable output that meets the needs of the deployment environment.

[0087] At block 406, the smart label 102 is peeled from the release liner 104, which breaks the breakable conductive trace 136 positioned in alignment with the tear-off tab window 118. The breakable conductive trace 136 is designed to sever when adequate force is applied during peeling. This force is provided by the tear-off tape strip 106, which is adhered to the release liner 104, and also to the activation tab 142. The tear-off tape strip 106 remains attached to the release liner 104 when the smart label 102 is removed, causing the activation tab 142 to be removed from the smart label 102, and remain with the release liner 104, thereby severing the breakable conductive trace 136. The breakable conductive trace 136 is electrically connected to an input port of the I / O ports 131 of the WPAN circuit 120, enabling the microcontroller 122 to monitor the trace status. The breakableAttorney Docket: MX-24467-WO-PCT conductive trace 136 serves as a physical trigger for activation, and its continuity or breakage is detected by the microcontroller 122 to initiate or control specific operational states within the smart label circuitry, such as powering on communication functions (e.g., the RF component 124) or activating sensors (e.g., the sensor(s) 134). As the smart label 102 is removed from the release liner 104, this break in the breakable conductive trace 136 changes a voltage level at an input port of the I / O ports 131 of the WPAN circuit 120, transitioning the WPAN circuit 120 from a low-power state to an active state and enabling the electronic components of the smart label 102. This automatic activation ensures a seamless transition from an unpowered to a powered state without requiring manual intervention, making it particularly useful for high-volume or automated deployments.

[0088] At block 408, once activated, the smart label 102 is applied to the intended surface, such as a product, package, or other asset, using the PSA layer 116, which provides a secure bond. The PSA layer 116 ensures adhesion across a range of surfaces, allowing the smart label 102 to remain attached and functional throughout its use. In this step, the smart label 102 transitions from a deployable state to an operational state, where the smart label 102 can begin performing its intended functions, such as sensing, tracking, or communication, enabled by the WPAN circuit 120. The reliable adhesion of the PSA layer 116, in combination with the labelstock 108 and the other protective layers, allows the smart label 102 to withstand environmental factors and operational stresses, ensuring durability and performance.

[0089] Optionally, the method 400 can include an inspection or testing step (not shown) to verify the successful activation of the smart label 102 and confirm its operational status. For instance, this step may involve checking the continuity of the WPAN circuit 120, signal strength from the RF component 124, and / or verifying that the sensor(s) 134 integrated within the FPC 112 are functioning correctly. Depending on the application requirements, this verification process may involve automated testing systems or manual inspections, ensuring that each smart label 102 or a tested subset is operational and ready for its designated role. This final inspection step provides quality assurance, confirming that the smart label 102 has been correctly activated and that the breakable conductive trace 136 has functioned as intended to initiate the electronic circuits.

[0090] The concepts and technologies disclosed herein provide a smart label web assembly 100 designed for efficient, automated activation and deployment of multiple smart labels 102(l)-102(N). Each smart label 102 features a multilayered construction,Attorney Docket: MX-24467-WO-PCT including a labelstock 108, a FPC 112 embedded with conductive traces, and a PSA layer 116 for secure attachment to various surfaces. A feature of the smart labels 102 is the breakable conductive trace 136 on the FPC 112, which enables automatic activation of the electronic components within each smart label 102 upon peeling from the release liner 104. This activation is facilitated by a tear-off tab window 118 in the PSA layer 116, which aligns with the tear-off tape strip 106 adhered to the release liner 104. When the smart label 102 is peeled away, the tear-off tape strip 106 exerts a controlled force on the breakable conductive trace 136, severing the trace and completing the activation circuit for its electronic components, such as the WPAN circuit 120.

[0091] Additionally, the concepts and technologies described herein enable streamlined programming and testing through programming points 138, accessible via windows in the PSA layer 116 before deployment. The continuous release liner 104 supports multiple smart labels 102 in a sequential arrangement, facilitating mass production and handling while preserving individual label integrity. This design allows the smart labels 102 to remain inactive during manufacturing and storage, preventing premature power drainage, and ensuring activation occurs precisely when applied to a target surface. The assembly thus provides a highly reliable, low-profde solution for realtime monitoring and tracking applications, with robust construction that accommodates diverse environmental and mechanical stresses.

[0092] The features, structures, or characteristics described above may be combined in one or more embodiments in any suitable manner, and the features discussed in the various embodiments are interchangeable, if possible. In the following description, numerous specific details are provided in order to fully understand the embodiments of the present disclosure. However, a person skilled in the art will appreciate that the technical solution of the present disclosure may be practiced without one or more of the specific details, or other methods, components, materials, and the like may be employed. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the present disclosure.

[0093] Although the relative terms such as “on,” “below,” “upper,” and “lower” may be used in the specification to describe the relative relationship of one component to another component, these terms are used in this specification for convenience only, for example, as a direction in an example shown in the drawings. It should be understood that if the device is turned upside down, the “upper” component described above will becomeAttorney Docket: MX-24467-WO-PCT a “lower” component. When a structure is “on” another structure, it is possible that the structure is integrally formed on another structure, or that the structure is “directly” disposed on another structure, or that the structure is “indirectly” disposed on the other structure through other structures.

[0094] In this specification, the terms such as “a,” “an,” “the,” and “said” are used to indicate the presence of one or more elements and components. The terms “comprise,” “include,” “have,” “contain,” and their variants are used to be open ended, and are meant to include additional elements, components, etc., in addition to the listed elements, components, etc. unless otherwise specified in the appended claims.

[0095] The terms “first,” “second,” etc. are used only as labels, rather than a limitation for a number of the objects. It is understood that if multiple components are shown, the components may be referred to as a “first” component, a “second” component, and so forth, to the extent applicable.

[0096] Disjunctive language, such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is to be understood with the context as used in general to present that an item, term, etc., can be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain implementations require at least one of X, at least one of Y, or at least one of Z to be each present.

[0097] The above-described implementations of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described implementation(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

Attorney Docket: MX-24467-WO-PCTCLAIMSWhat is claimed is:

1. A smart label comprising: a flexible printed circuit (FPC) configured to support electronic components, including a wireless personal area network (WPAN) circuit with a microcontroller and a radio frequency component; a battery attached to the FPC and configured to supply power to the WPAN circuit; a pressure-sensitive adhesive (PSA) layer positioned beneath the FPC and configured to secure the smart label to a surface; and a breakable conductive trace electrically connected to an input port of the WPAN circuit, the breakable conductive trace configured to sever upon peeling of the smart label from a release liner, wherein severing the breakable conductive trace changes a voltage level at the input port to transition the WPAN circuit from a low-power state to an active state.

2. The smart label of claim 1, wherein the PSA layer includes a pre-cut tear- off tab window aligned with the breakable conductive trace.

3. The smart label of claim 1, further comprising one or more sensors integrated on the FPC and configured to communicate data to the WPAN circuit.

4. The smart label of claim 3, wherein the one or more sensors include a temperature sensor, a humidity sensor, an accelerometer, a gyroscope, a light sensor, a proximity sensor, a pressure sensor, or a gas sensor.

5. The smart label of claim 1, further comprising programming points positioned on or near an activation tab of the FPC, allowing for initial programming and configuration of the smart label.

6. The smart label of claim 1, wherein the WPAN circuit includes a matching network and an antenna configured to facilitate short-range wireless communication.

7. The smart label of claim 1, wherein the FPC further comprises a ground plane configured to reduce electromagnetic interference and enhance signal integrity.Attorney Docket: MX-24467-WO-PCT8. The smart label of claim 1, wherein the PSA layer comprises an acrylic, rubber-based, or silicone-based adhesive formulated to maintain adhesion under varying environmental conditions.

9. A smart label web assembly comprising: a release liner; a plurality of smart labels arranged on the release liner, each smart label of the plurality of smart labels comprising: a flexible printed circuit (FPC) configured to support electronic components; a battery attached to the FPC; a breakable conductive trace electrically connected to an input port of the electronic components, the breakable conductive trace configured to sever upon peeling from the release liner, wherein severing the breakable conductive trace changes a voltage level at the input port to transition the electronic components from a low-power state to an active state; and a tear-off tape strip aligned with the breakable conductive trace of each smart label of the plurality of smart labels and configured to apply a controlled force to sever the breakable conductive trace upon peeling from the release liner.

10. The smart label web assembly of claim 9, wherein each smart label includes a pressure-sensitive adhesive (PSA) layer with a pre-cut tear-off tab window aligned with the breakable conductive trace.

11. The smart label web assembly of claim 9, wherein each smart label further includes one or more sensors in communication with a microcontroller within the FPC.

12. The smart label web assembly of claim 9, further comprising programming points on each FPC, configured to allow programming of operational parameters for each smart label.Attorney Docket: MX-24467-WO-PCT13. The smart label web assembly of claim 9, wherein the tear-off tape strip is adhered to the release liner and remains on the release liner when the smart label is peeled away.

14. The smart label web assembly of claim 9, wherein the release liner and the tear-off tape strip are configured to sequentially expose each smart label for deployment and activation.

15. The smart label web assembly of claim 9, wherein the tear-off tape strip is laminated in register with each pre-cut tear-off tab window to align with an activation tab of each smart label.

16. A method for manufacturing a smart label web assembly, comprising: forming a tear-off tab window in a pressure-sensitive adhesive (PSA) layer; aligning a flexible printed circuit (FPC) and a battery in register with the PSA layer, wherein the FPC includes a breakable conductive trace; laminating a labelstock over the FPC and the PSA layer; and cutting the labelstock and PSA layer to define individual smart labels on a release liner.

17. The method of claim 16, further comprising laminating a tear-off tape strip in register with each pre-cut window to align with the breakable conductive trace on each FPC.

18. The method of claim 16, further comprising programming each smart label by interfacing with exposed programming points through the pre-cut window.

19. The method of claim 16, further comprising placing spacers between adjacent FPCs to prevent compression or unintended contact between neighboring components.Attorney Docket: MX-24467-WO-PCT20. The method of claim 16, wherein cutting further comprises defining boundaries of each smart label through the labelstock layer and the PSA layer without penetrating the release liner.

21. The method of claim 16, further comprising testing each smart label after programming to verify activation functionality and operational parameters.

22. A method for deploying and activating a smart label, comprising: peeling a tear-off tape strip from a release liner to expose an activation tab aligned with a tear-off tab window of a PSA layer; and peeling the smart label from the release liner, thereby severing a breakable conductive trace positioned in alignment with the activation tab, wherein severing the breakable conductive trace changes a voltage level at an input port of a wireless personal area network (WPAN) circuit to transition the WPAN circuit from a low-power state to an active state.

23. The method of claim 22, further comprising applying the smart label to an asset surface using the PSA layer.

24. The method of claim 22, further comprising verifying the activation of the WPAN circuit upon deployment.

25. The method of claim 22, further comprising monitoring environmental conditions via one or more sensors integrated within the smart label after activation.

26. The method of claim 22, further comprising configuring the WPAN circuit to enter a low-power mode after initial activation to conserve battery life.

27. The method of claim 22, further comprising automatically transmitting data from the WPAN circuit to an external device after activation.

28. The method of claim 22, further comprising securing the smart label in an operational position on a target asset.

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