RFID Bead Label Layers for Vulcanization-Resistant Tire Identification
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Solution Overview
Problem
Conventional RFID and barcode labels used on rubber articles, such as tires, are rendered inoperable by the harsh conditions of vulcanization processes, including high temperatures and pressures, leading to inefficiencies and increased costs due to the need for additional labeling post-cure and potential errors in identifying pre-cure identifiers.
Innovation Solution
An RFID bead label device with a protective topcoat, rubber adhesion layer, heat-resistant polyimide layer, and polyester layers that maintain RFID operability during and after vulcanization, allowing simultaneous identification without line-of-sight requirements and enabling data writing during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional RFID labels are used on rubber articles during vulcanization, then identification can occur during manufacturing, but the labels are rendered inoperable by high temperature and pressure
Solution Approach 1:
The RFID label uses a composite structure with multiple specialized layers: a polyimide substrate layer that provides heat resistance, a silicone adhesive layer for bonding, a protective overcoat layer, and an RFID inlay with antenna and chip. This composite material structure enables the label to withstand vulcanization temperatures and pressures while maintaining RFID functionality.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the label materials to withstand vulcanization conditions. The polyimide substrate is selected for its high thermal stability, the silicone adhesive is formulated to remain flexible and adhesive at elevated temperatures, and the overall label construction is designed to maintain structural integrity under pressure and heat, thereby preserving RFID operability throughout the vulcanization process.
2Temperature
If barcode-only labels are used to withstand high temperatures, then heat resistance is achieved, but line-of-sight scanning requirements and inability to write data during production occur
Solution Approach 1:
The patent merges the heat-resistant barcode label functionality with RFID capabilities into a single integrated label structure. The barcode layers provide thermal stability and heat resistance, while the RFID inlay embedded within the same label structure provides wireless identification without line-of-sight requirements and enables data writing during production.
Solution Approach 2:
The label is designed to perform multiple functions simultaneously: it provides visual barcode identification for scanning, wireless RFID identification for contactless reading and data writing, and maintains heat resistance for vulcanization exposure. This multi-functional design eliminates the need for separate labeling systems.
3Measurement precision
If additional labeling is performed post-cure, then identification accuracy is maintained, but time and cost increase
Solution Approach 1:
The RFID label is applied to the rubber article before vulcanization (pre-cure) rather than after. The label is designed to withstand the subsequent vulcanization process, eliminating the need for post-cure labeling. This preliminary action saves time and allows the label to be integrated into the manufacturing process flow.
Solution Approach 2:
The patent uses a disposable adhesive label construction that is inexpensive to produce and apply. The label is designed as a single-use component that is applied once before vulcanization and maintains functionality throughout the manufacturing process, eliminating the need for additional labeling operations and associated costs.
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 device withstands temperatures up to 220°C for 12 hours, maintaining RFID functionality throughout the manufacturing process, reducing errors and costs by allowing continuous identification and data sharing, and eliminating the need for post-cure labeling.
Implementation Method 1
a polyimide layer with heat resistant RFID capabilities... maintains RFID operability during vulcanization and post-vulcanization of the rubber article
Implementation Method 2
an adhesive layer positioned between and bonding together the topcoat, the polyester layers, the polyimide layer, and the rubber adhesion layer
Data Source
AI summary
Disclosed are pre-cure RFID-enabled bead labels based on an RFID inlay construction consisting of an aluminum antenna etched on to a high temperature resistant polyimide film that is connected to an integrated memory circuit positioned on the surface of the polyimide film. This RFID inlay being further inserted into an overall label construction having a generally arcuate or semi-arcuate shape and a plurality of layers that include, for example, a plurality of polyester layers and a plurality of high temperature resistant adhesive layers that bond/adhere layers together, the plurality of layers further protecting and insulating the RFID inlay while the label is bonded to the external bead (or sidewall) of a tire. The compositions/devices disclosed herein can be used for electronic identification when applied on rubber-based articles (e.g., tires) prior to being subjected to stress related to the vulcanization process and normal use of this article during the manufacturing process.