RF Tag Laminate Roller Bonding With Inclined Tag Layout
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Solution Overview
Problem
Air can remain between rubber sheet layers and RF tags during the manufacturing of RF tag laminates, degrading the durability of the resulting laminates, and existing methods struggle to produce highly durable laminates with high productivity.
Innovation Solution
A method involving the arrangement of RF tags on a rubber sheet layer with inclined long sides relative to the roller's movement direction, followed by pressure-bonding with rollers to ensure air escape and secure bonding without adhesives, using unvulcanized rubber sheets for the coating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple RF tags are arranged on rubber sheet layers and pressure-bonded together, then productivity is improved by obtaining multiple RF tag laminates at once, but air remains between the rubber sheet layers and RF tags degrading durability
Solution Approach 1:
The patent applies asymmetry by arranging RF tags at inclined angles (specifically 45 degrees) relative to the rolling direction of the rubber sheet layers. This asymmetric arrangement creates diagonal pathways that facilitate air escape during pressure bonding, while maintaining high productivity through batch processing of multiple RF tags simultaneously.
Solution Approach 2:
The patent implements preliminary action by pre-positioning multiple RF tags on the rubber sheet layers before the pressure bonding process. The tags are arranged in advance with proper spacing and inclination, allowing the bonding process to proceed efficiently without requiring subsequent air removal steps, thus maintaining both high productivity and durability.
2Ease of manufacture
If RF tags are arranged parallel to the rolling direction for easy alignment, then ease of manufacture is improved, but air becomes trapped between layers reducing bonding quality
Solution Approach 1:
Instead of arranging RF tags parallel to the rolling direction (symmetric alignment), the patent uses an asymmetric 45-degree inclination arrangement. This maintains ease of manufacture through systematic positioning while creating effective air escape pathways that significantly improve bonding quality and eliminate air entrapment.
Solution Approach 2:
The patent transitions from one-dimensional alignment (parallel to rolling direction) to a two-dimensional inclined arrangement. This dimensional change allows air to escape along diagonal pathways created by the inclined tag arrangement, improving bonding quality while maintaining manufacturing efficiency through structured positioning.
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
This method enables the production of highly durable RF tag laminates with improved productivity by effectively removing air and ensuring strong adhesion between layers, enhancing the laminate's durability.
Implementation Method 1
a first roller 3a moves on, and relative to, the first rubber sheet layer 11a, the plurality of RF tags 10, and the second rubber sheet layer 11b (stacked sheet), in a direction intersecting the long sides 10aL of the rectangular shape of the IC chips 10a
Data Source
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AI summary
A method of manufacturing RF tag laminates includes an RF tag arranging step, a second rubber sheet layer stacking step, and a roller pressure-bonding step, wherein, in the RF tag arranging step, a plurality of RF tags 10 are arranged on a first rubber sheet layer 11a in a manner such that long sides 10aL of a rectangular shape of an IC chip 10a of each RF tag 10 in the plurality of RF tags 10 are inclined with respect to a direction RMV orthogonal to a relative movement direction RM of a first roller 3a in a plan view.