Baler twine with integrated connectivity

Abstract

The present application describes a Baler Twine with integrated connectivity. The proposed baling twine is suitable for agricultural baling operations and is composed by a plurality of twisted synthetic fibres. It is characterized by comprising a RFID tag directly applied to the plurality of twisted synthetic fibres during its extrusion process.

Description

Baler Twine with integrated connectivity

[0001] The present invention describes a RFID device and method to apply it on baler twine. The RFID tag is specifically designed to be directly applied to a raffia tape during the extrusion process while withstanding the mechanical stress and torsional effects of the twisting of the tape to become baler twine.

[0002] The use of plastics in agriculture dates back to the early beginning of industrial plastic production in the 1950s. "Plasticulture" is a guarantee of income for farmers worldwide, promoting increased production, improved product quality and, above all, reducing the environmental footprint of agricultural activity. Similarly, regarding equipment used in agriculture, technology is increasingly working in favour of the farmer, assisting in the selection and prioritisation of harvests with more advanced levels of ripeness. This enables scheduling based on available loads and volumes for transport and storage, while also controlling sugar content, humidity levels, freshness indices, etc.

[0003] In the case of individual bales, the challenge, particularly in markets with large estate profile such as the USA, Canada, Brazil, Argentina, Australia, among others, is for each producer to know exactly the quantity they have available and the conditions of those bales. This enables FIFO (First-In, First-Out) management of forage for feeding, geolocation of dispersed stocks for livestock movements, among many other benefits.

[0004] The challenge for Original Equipment Manufacturer (OEM) is straightforward: equip machinery with the ability to store this information and transfer it to each bale. The challenge for the user, however, may not be so simple, as it currently involves an added cost in investing in marking devices. The main problem here is that these devices are often lost or taken by animals.

[0005] Prior art related to the present invention can be divided in two categories: (1) Inventions related to balers and tagging devices, specific for the agricultural crop baling applications, like US 9,943,036 by Verhaeghe et al., US 10,037,484 by Foster et al., and US 10,303,997, US 10,492,371 and US 10,657,433 by Hamilton et al. (2) Inventions related to the binding filament or baler twine, namely US 2020 / 0074262 and US 2020 / 0128754 by Hamilton et al.

[0006] The inventions related to the balers and tagging devices, could be used as a complement of the present invention, provided that the working frequencies and data logging are standardized and compatible with the RFID technology developed by the present invention.

[0007] On the other hand, the present invention shows several advantages when compared to Hamilton et al. applications. Unlike the present invention, Hamilton et al. applications are based on an extra filament that carries the RFID inlay parallel to the baler twine or twisted together with the baler twine rendering the solution more difficult to use in the field and more demanding for the baling process.

[0008] Baler twine is mainly used for baling, specifically as an individual crop packaging solution. Synthetic baler twine is produced out of extruded polypropylene raffia tapes, usually fibrillated for higher flexibility and smoothness, that are twisted into twine.

[0009] The present invention is related to the development of an RFID device and method to apply it on baler twine. The developed RFID device, or RFID tag, is specifically designed to be directly applied to a raffia tape during its extrusion process, being the RFID device able to withstand the mechanical stress and torsion effects of the twisting of the raffia tape to become baler twine.

[0010] The baler twine thus comprising said RFID tag presents integrated connectivity whilst keeping its basic function, use and applicability. The final proposed product is an integral solution, eliminating the need for applying extra tags or any other external elements on the final bale, as well as extra tagging steps throughout the baling process. Fully connected bales become the end results of a single baling step.

[0011] The present invention also conceives an industrial process for applying the RFID technology with minimal impact on the current production process (maximum estimated production loss of 10%).

[0012] The present invention describes a baling twine suitable for agricultural baling operations, composed by a plurality of twisted synthetic fibres, being characterized by further comprising a RFID tag directly applied to the plurality of twisted synthetic fibres during its extrusion process.

[0013] In a proposed embodiment of present invention, the RFID tag is suitable for withstanding mechanical and torsional stress effects during the twisting of the plurality of synthetic fibres.

[0014] Yet in another proposed embodiment of present invention, the plurality of twisted synthetic fibres comprises an extruded polypropylene raffia tape or an extruded polypropylene fibrillated raffia tape.

[0015] Yet in another proposed embodiment of present invention, the RFID tag comprises a stacked inlay layer over a substrate layer on which a UHF Chip is connected to a printed dipole antenna, which are further protected by means of an encapsulation agent.

[0016] Yet in another proposed embodiment of present invention, the RFID tag comprises an adhesive layer, on which the substrate layer is laid, and which further enables adherence of the RFID tag to the plurality of twisted synthetic fibres during the extrusion process.

[0017] Yet in another proposed embodiment of present invention, the RFID tag comprises a width of 20 mm, preferably set between 12 mm and 15 mm; and / or a length of 200 mm, preferably set between 170 mm and 180 mm; and / or a thickness of 500 µm, preferably set between 295 µm and 325 µm.

[0018] Yet in another proposed embodiment of present invention, the substrate comprises a thickness of 100 µm, preferably set between 70 µm and 85 µm; and / or by comprising a flexible polymer like polyolefin or polyester or polyamide, preferably polypropylene or polyethylene terephthalate.

[0019] Yet in another proposed embodiment of present invention, the printed dipole antenna comprises two linear arms with 100 mm length each, and / or with 2 mm width each, and / or with 20 µm thickness each.

[0020] Yet in another proposed embodiment of the present invention, the antenna is printed with a conductive ink, like copper, carbon and / or silver-based inks, preferably a silver-based ink.

[0021] Yet in another proposed embodiment of present invention, the adhesive comprises a preferred thickness of 150 µm.

[0022] Yet in another proposed embodiment of present invention, the encapsulation agent comprises a liquid or gel polymer with fast curing, like silicone base liquid rubber, polyurethane or polyethylene terephthalate glycol, preferably polyethylene terephthalate glycol.

[0023] The current invention further describes the method to produce the baling twine previously described, characterized by comprising the following steps: extrusion of the synthetic fibres; stretching the extruded synthetic fibres; fibrillation of the stretched synthetic fibres; integration of RFID tag in the fibrillated synthetic fibres; winding of the fibrillated synthetic fibres with the integrated RFID tag; twisting of the winded synthetic fibres with the integrated RFID tag.

[0024] Baler twine is mainly used for baling, specifically as an individual crop packaging solution. Synthetic baler twine is produced out of extruded polypropylene raffia tapes, usually fibrillated for higher flexibility and smoothness, that are twisted into twine.

[0025] RFID technology uses radio frequency to automatically identify and locate tags placed on a wide variety of objects and is used in various applications such as logistics, animal identification, asset tracking, electronic passports, shop security, etc. In these applications, tags are used that store information electronically and can be classified according to two criteria: the radio frequency band they use to communicate and how the tag communicates with the reader.

[0026] Regarding the first criterion, RFID tags can be grouped into three categories: low frequency (LF), high frequency (HF) and ultra-high frequency (UHF). LF systems operate between 30kHz and 300kHz and have a range that can reach up to 10 metres. These systems perform better in the presence of liquids and metal compared to the other two categories. HF systems operate between 3 MHz and 30 MHz and have a range from 10 cm to 1 m. As for the UHF category, these have a frequency range that is between 300 MHz and 3 GHz and have ranges that can reach up to 12 metres. Furthermore, they have the fastest data transfer rate.

[0027] With regard to the second criterion, RFID tags can be classified as active, passive and semi-passive. Active tags have their own transmitter and power source, which allows for a reading range that can reach 100 m. They are larger and more expensive tags compared to passive ones. As for passive tags, these do not have their own power supply; when the reader sends a signal to the RFID tag, it energises it and the tag in turn reflects the energy back to the reader. The reading ranges for these tags are smaller than in active tags and are limited by the power of the radio signal reflected back to the antenna. Passive tags are smaller, less expensive and more flexible. Semi-passive tags have a power source, but do not have their own transmitter. The power source is used to ensure that all the energy from the reader's antenna is used, thus increasing the reading distance and data transfer rate.

[0028] The motivation for the present invention is to develop the first smart twine on the market, meeting OEM specifications in terms of twine strength and integrated Radio Frequency Identification (RFID) technology, while also simplifying the work and daily routine of the producer. Ultimately, this allows producers to take advantage of all the benefits offered by their modern agricultural equipment without any extra effort. Applying an Industry 4.0 logic to a commodity product, the present invention will enable all production data for each bale, deemed relevant by the farmer, to be recorded directly onto the bale itself, thus being the first agricultural baler twine with integrated connectivity, eliminating the need for end-users to attach tags or any other accessories to the bale, thus removing redundant extra work.

[0029] The present invention dismisses the use of external tags or secondary filament as carrier of the RFID inlay, given that the binding twine is the carrier of the RFID inlay.

[0030] As per the present invention, nothing changes for the baler twine and baling machine end-user, that can work its equipment and supplies without the need for specific adjustments or even mechanical / structural changes.

[0031] Direct integration of RFID technology on the Baler Twine allows for a product with integrated connectivity while keeping its basic function, use and applicability. The solution dismisses the use of extra tags or any other external elements on the final bale, as well as extra tagging steps throughout the baling process. Fully connected bales are the final product in a single baling step.

[0032] The integrated RFID technology is designed to respond to every reading / writing technology and frequency available to the end user, being the baling machine integrated system or any other type of electronic logging device.

[0033] Based on the previously mentioned characteristics, for the current development, the choice of the RFID technology should fall on passive UHF tags in order to obtain a product with smaller dimensions, flexible, with a sufficient reading range and without the need for maintenance.

[0034] The application includes two different aspects: the first is related with the development of and RFID element to be applied to the baler twine during its production; the second is related with the synthetic baler twine with common functionality and characteristics with the benefits of the integrated connectivity.

[0035] The main challenge and novelty reside in the RFID element, developed to withstand the mechanical stress and torsion efforts involved in the production of the baler twine, while keeping its functionality and minimum reading / writing distance of 1 meter. The second challenge is related with the baler twine, a commodity product used for binding bales of feedstock crops, waste of paper or plastic, wood, just to name a few, presenting extra functionality with integrated connectivity.

[0036] The overall advantage of the proposed final product is a one step-one product solution for full identification, traceability and even geolocation for baled goods, compatible with every electronic registration / recording / reading technology available for RFID integrated circuits.

[0037] For better understanding of the present application, figures representing preferred embodiments are herein attached which, however, are not intended to limit the technique disclosed herein.

[0038] illustrates a possible embodiment and representation of the RFID tag.

[0039] illustrates a possible embodiment and representation of a cross-sectional view of the RFID tag.

[0040] illustrates a possible embodiment for the RFID tag final application on the baler twine substrate.

[0041] illustrates the step-by-step procedure to obtain a baler twine with integrated connectivity, comprising the RFID tag.

[0042] With reference to the figures, some embodiments are now described in more detail, which are however not intended to limit the scope of the present application.

[0043] The present invention includes the development of an RFID inlay, in form of a flexible self-adhesive tag (200), designed specifically to be applied to the surface of a polypropylene raffia tape (110), during the extrusion process.

[0044] The developed RFID tag (200) is illustrated in. Additionallyillustrates a cross-sectional view of the proposed RFID tag (200).

[0045] The RFID tag (200) described in the present invention disclosure comprises a range of preferred characteristics.

[0046] The RFID tag (200) comprises a width (10) preferably comprised between 12 mm and 15 mm, with a preferred maximum of 20 mm.

[0047] The RFID tag (200) comprises a length (20) preferably comprised between 170 mm and 180 mm, with a preferred maximum of 200 mm.

[0048] The RFID tag (200) comprises a thickness (30) preferably comprised between 295 µm and 325 µm, with a preferred maximum of 500 µm.

[0049] The RFID tag (200) comprises a substrate (40) preferably comprising a thickness between 70 µm and 85 µm, with a preferred maximum of 100 µm. The tag substrate (40), in a preferred embodiment, comprises a flexible polymer, with enough mechanical resistance and density similar to raffia tape (110), like flexible polyolefin, polyester or polyamide, more preferably polypropylene, and even more preferably polyethylene terephthalate.

[0050] The RFID tag (200) comprises a printed dipole antenna (50) comprised of two linear arms, with a preferred maximum length of 100 mm each, with a preferred width of 2 mm and preferred maximum thickness of 20 µm. In a preferred embodiment, the dipole antenna (50) is printed with conductive ink, resistant to mechanical stress and temperature exposure, like copper, carbon and silver-based inks, more preferably with a silver-based ink.

[0051] The RFID tag (200) comprises a UHF Chip (60), responsive to radio-frequency ranges within some countries like Europe, USA and Asia, i.e., in Europe from 470 MHz to 790 MHz, in the USA from 470 MHz to 806 MHz, and in Asia from 470 MHz to 806 MHz. The UHF chip (60) dimensions (area) in a preferable embodiment should not exceed 500 µm2. The UHF Chip (60) integrated circuitry is connected to the dipole antenna (50) by means of an anisotropic adhesive.

[0052] The RFID tag (200) comprise self-adhesive properties to allow for easy and automatic transfer to final product. The RFID tags (200) comprise particular properties that enable the immediate adhesion to a polypropylene raffia tape (110) surface. The RFID tag (200) comprises a back-layer which is comprised of an adhesive (70) feature whose thickness does exceeds 150 µm in a preferred embodiment.

[0053] In a possible embodiment of the invention, the RFID tag (200) comprises an inlay (90) which is applied to the substrate (40) and protected by means of an encapsulation agent (100). The encapsulation agent (100) is a liquid or gel polymer with fast curing like silicone base liquid rubber, polyurethane or polyethylene terephthalate glycol, more preferably polyethylene terephthalate glycol.

[0054] In a possible embodiment of the invention, the RFID tag (200) is flexible, mechanically and thermally resistant to allow for a seamless application and integration in a baler twine (130). During integration, and final use, the RFID tag (200) ensures high mechanical stress, particularly torsional effects, so that the welding and fixation elements between antenna (50) and chip (60) are necessarily strong. To enable these characteristics, a linear design for the tag was developed as to withstand the mechanical efforts, specifically friction and torsional stresses, in final application with minor damage and higher functionality.

[0055] Final reading / writing distance between a reading source (or device) and the RFID tag (200) should be no less than one meter. This distance is set to be considered under the application within the final product, the final twisted baler twine (130), after the twisting procedures.

[0056] Under original conditions, and before applying the RFID tag (200) on the final product, the usual and original reading / writing distance from a reading source and the RFID tag (200) should be greater than three meters.

[0057] In a proposed embodiment, the RFID tags (200) are to be integrated and applied continuously in the baler twine (130) within a distance not superior to 1,6 meters, preferably between 0,8 and 1,2 meters apart.

[0058] To allow for automatic easy peel and stick application of the RFID tags (200) during the extrusion process, the tags should be in roll form, rolled with narrow leading edge, longitudinally placed in a carrier substrate paper (250), as illustrated in.

[0059] The RFID tags (200) are to be applied during the raffia tape (110) extrusion process, by means of a modified automatic labelling machine working in-line, positioned after the stretching and fibrillation rolls, preferably before winding step as illustrated in.

[0060] The overall process of obtaining a Baler Twine with integrated connectivity (130) results from the process of integration of RFID tags (200) into a raffia tape (110) which can be described accordingly with the steps of: extrusion of the raffia tape (1000); stretching the extruded raffia tape (1001); fibrillation of the stretched raffia tape (1002); integration of RFID tag in the fibrillated raffia tape (1003); winding of the fibrillated raffia tape with the integrated RFID tag (1005); twisting of the winded raffia tape with the integrated RFID tag (1006).

[0061] The RFID tags (200) are to be applied after the fibrillation roll, preferably before the final nip roll in a preferred central position of the tape (110), like illustrated in, in such way that upon winding, the raffia tape (110) folds naturally over itself protecting the RFID tag (200). The raffia tape (110) and RFID tag (200) follow through the next stage of twisting in such, that the RFID tag (200) becomes seamless twisted in the polypropylene baler twine (130), as represented in.

[0062] The invention is to be used primarily in the agricultural market, as individual crop packaging. Also, agricultural baling machines are evolving fast, and some brands already envision the reading / writing function for a complete bale traceability, which is particularly important in large properties and extensive agricultural productions like the ones in USA, Australia, Canada, France, UK, just to name a few.

[0063] Crop baling is a large business encompassing animal farming, feedstock production and even biomass energy plants.

[0064] Other types of markets / industries where baled goods are used could also benefit from the baler twine with integrated technology.

[0065] (10) - Tag width

[0066] (20) - Tag length

[0067] (30) - Tag thickness

[0068] (40) - Tag substrate

[0069] (50) - Tag dipole antenna

[0070] (60) - Tag UHF Chip

[0071] (70) - Tag adhesive

[0072] (90) - inlay

[0073] (100) - encapsulation agent

[0074] (110) - raffia tape

[0075] (130) - twisted baler twine

[0076] (200) - RFID tag

[0077] (250) - carrier substrate paper

[0078] (300) - Empty space between tags

[0079] (400) - Distance between tags depends on the number of tags per meter

[0080] (1000) - PP raffia tape extrusion

[0081] (1001) - PP raffia tape stretching

[0082] (1002) - PP raffia tape fibrillation

[0083] (1003) - Direct Integration of RFID inlay

[0084] (1004) - RFID inlay development

[0085] (1005) - PP raffia tape winding

[0086] (1006) - PP raffia tape twisting

[0087] (1007) - Baler Twine with integrated connectivity

Claims

A baling twine (130) suitable for agricultural baling operations, composed by a plurality of twisted synthetic fibres, being characterized by further comprising a RFID tag (200) directly applied to the plurality of twisted synthetic fibres during its extrusion process.Baling twine (130) according to the previous claim, characterized by the RFID tag (200) being suitable for withstanding mechanical and torsion stress effects during the twisting of the plurality of synthetic fibres.Baling twine (130) according to any of the previous claims, characterized by the plurality of twisted synthetic fibres comprising an extruded polypropylene or fibrillated raffia tape.Baling twine (130) according to any of the previous claims, characterized by the RFID tag (200) comprising a stacked inlay (90) layer over a substrate (40) layer on which a UHF Chip (60) is connected to a printed dipole antenna (50), which are further protected by means of an encapsulation agent (100).Baling twine (130) according to any of the previous claims, characterized by the RFID tag (200) comprising an adhesive (70) layer, on which the substrate (40) layer is laid, and which further enables adherence of the RFID tag (200) to the plurality of twisted synthetic fibres during the extrusion process.Baling twine (130) according to any of the previous claims, characterized by the RFID tag (200) comprising a width (10) of 20 mm, preferably set between 12 mm and 15 mm; and / or a length (20) of 200 mm, preferably set between 170 mm and 180 mm; and / or a thickness (30) of 500 µm, preferably set between 295 µm and 325 µm.Baling twine (130) according to any of the previous claims, characterized by the substrate (40) comprising a thickness of 100 µm, preferably set between 70 µm and 85 µm; and / or by comprising a flexible polymer like polyolefin or polyester or polyamide or polypropylene or polyethylene terephthalate.Baling twine (130) according to any of the previous claims, characterized by the dipole antenna (50) comprising two linear arms with 100 mm length each, and / or with 2 mm width each, and / or with 20 µm thickness each.Baling twine (130) according to any of the previous claims, characterized by the dipole antenna (50) being printed with a conductive ink comprising copper, carbon and / or silver.RFID tag (200) according to any of the previous claims, characterized by the adhesive (70) comprising a preferred thickness of 150 µm.RFID tag (200) according to any of the previous claims, characterized by the encapsulation agent (100) comprising a liquid or gel polymer with fast curing like silicone base liquid rubber, polyurethane or polyethylene terephthalate glycol, preferably polyethylene terephthalate glycol.Method to produce the baling twine (130) described in any of the previous claims 1 to 10, characterized by comprising the following steps: extrusion of the synthetic fibres (1000); stretching the extruded synthetic fibres (1001); fibrillation of the stretched synthetic fibres (1002); integration of RFID tag in the fibrillated synthetic fibres (1003); winding of the fibrillated synthetic fibres with the integrated RFID tag (1005); twisting of the winded synthetic fibres with the integrated RFID tag (1006).

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