Laser-Tuned RFID Tag Attachment for Garment Reliability
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Solution Overview
Problem
Existing RFID tag solutions face challenges such as difficulty in removing tags from Point Of Sale systems without damage, high failure rates during sewing into cloth, and visibility or irritation issues when attached to garments.
Innovation Solution
A method and system for producing RFID tags using a thin, narrow substrate with electronic components mounted on it, which can be laser-tuned and attached to items using a heat source, allowing for optimal performance based on the item's dielectric and tuning properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard sewing techniques are used to attach RFID tags to cloth, then the attachment process is simple and inexpensive, but the RFID tag failure rate increases to 1-20%
Solution Approach 1:
The patent replaces mechanical sewing attachment with ultrasonic welding, which uses ultrasonic vibration energy to melt and bond the RFID tag to the fabric. This substitution eliminates needle punctures that damage RFID tags while maintaining automated attachment capability, reducing failure rates from 1-20% to below 1%
Solution Approach 2:
The patent utilizes phase transition of the bonding material from solid to molten state through ultrasonic heating, then back to solid upon cooling. The ultrasonic vibration generates localized heat that melts the bonding material, which then bonds the RFID tag to the fabric when cooled, creating a secure attachment without mechanical damage
2Ease of operation
If RFID tags are placed on care or brand labels, then the tags are easy to access, but the tags become easy to remove and may cause irritation to wearers
Solution Approach 1:
The patent incorporates the RFID tag directly into the garment fabric during the manufacturing process, specifically embedding it within the seam structure. This preliminary integration ensures the tag cannot be easily removed by consumers, preventing theft while remaining imperceptible to wearers through proper placement and bonding techniques
3Adaptability or versatility
If RFID tags are attached to garments with substantial interfering material or near reader thresholds, then the tags can be attached to various garment types, but the RFID communication performance deteriorates
Solution Approach 1:
The patent implements dynamic tuning of the RFID tag antenna parameters based on the specific garment material and construction. The system adjusts antenna length, width, and configuration to compensate for dielectric interference from different fabrics and layers, optimizing RFID communication performance for each garment type while maintaining versatility across product lines
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides RFID tags that are thin, difficult to feel or see when integrated into items, and offer improved security and performance by being specifically tuned for each type of item, reducing failure rates and visibility issues.
Implementation Method 1
A laser is used to remove portions of the conductive trace (e.g., by decreasing a thickness, width, or height of the conductive trace)
Implementation Method 2
The portion of the narrow substrate is then coupled to the item so as to incorporate the tag in or with the item
Implementation Method 3
The portion of the narrow substrate is then coupled to the item so as to incorporate the tag in or with the item
Data Source
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AI summary
Aspects of the present disclosure relate to methods and systems for laser turning and attaching RFID tags to products. Such methods and systems may include a memory and a processor coupled to the memory. The methods and systems may include determining a characteristic of a conductive trace on a substrate to be incorporated into an item to configure a tag performance in view of at least one of a dielectric property or a tuning property of the item. The methods and systems may further include a laser to alter the conductive trace on the substrate to have the characteristic to define an antenna for the tag. The methods and systems may further include an attaching device configured to attach a communications enabled device to the substrate so as to form an electrical connection between the communications enabled device and the antenna to form the tag.