RFID Tag Integrated into Printed Fabric Label
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Solution Overview
Problem
Existing RFID tags, particularly passive ones, face limitations in cost, size, and read range due to the need for external power sources, and there is a need for a cost-effective and sustainable solution for tracking items using radio-frequency identification in various environments.
Innovation Solution
An RFID tag is integrated into a printed fabric label (PFL) using a conductive foil laminated on fabric, with a chip or strap attached via adhesive, allowing for flexible attachment methods and minimizing material usage, such as using a releasable adhesive and cutting techniques like laser cutting to define the antenna pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passive RFID tags are used without external power sources, then cost is reduced, but read range and activation reliability deteriorate
Solution Approach 1:
The patent combines the RFID tag with a printed fabric label, integrating the antenna and chip into a single manufactured unit. This merging allows the tag to be produced cost-effectively through printing and lamination processes while maintaining reliable activation through optimized antenna design and material selection.
Solution Approach 2:
The patent changes the physical and electrical parameters of the antenna system by using conductive ink printed on fabric substrates with specific electromagnetic properties. By adjusting ink composition, layer thickness, and fabric material parameters, the system achieves reliable activation at passive tag cost structures.
2Manufacturing precision
If conductive foil is laminated on fabric and then cut to define antenna pattern, then manufacturing precision is improved, but material waste increases
Solution Approach 1:
The patent segments the conductive foil application process by first applying foil only to areas where antenna patterns will be formed, rather than covering the entire fabric surface. This segmentation reduces material waste while maintaining manufacturing precision through targeted foil placement followed by precise cutting.
Solution Approach 2:
The patent extracts and removes excess conductive foil material after the antenna pattern is defined through cutting. This extraction process eliminates unnecessary material while preserving the precision of the antenna pattern, converting a waste-generating process into a controlled material removal operation.
3Reliability
If RFID tags are permanently attached to articles, then tracking reliability is improved, but adaptability deteriorates
Solution Approach 1:
The patent employs dynamic attachment characteristics by using adhesives that provide initial permanence for tracking reliability while allowing for controlled removal and reattachment. This dynamic property enables the tag to maintain reliable tracking during use while adapting to different attachment locations and articles throughout its lifecycle.
Solution Approach 2:
The patent changes the adhesive bond strength parameter over time and under different conditions, allowing the tag to be permanently fixed during normal operation for reliable tracking, yet removable when adaptation is needed. This parameter change enables both tracking reliability and attachment flexibility to coexist.
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 approach enables cost-effective, compact, and recyclable RFID tags that can be easily integrated into apparel and other items, improving tracking efficiency and inventory control while reducing material waste and increasing read range capabilities.
Implementation Method 1
a conductive sheet or foil such as aluminum is laminated on a fabric material via a releasable adhesive
Implementation Method 2
a chip or a strap having a chip or integrated circuit mounted thereon is then attached with a thin layer of a conductive pressure sensitive adhesive
Implementation Method 3
the foil may be cut via a cutter such as a laser or mechanical die cutter in order to define the pattern of the antenna
Data Source
AI summary
An RFID tag is disclosed that is formed as part of a printed fabric label (PFL). Generally, foil is adhered to a fabric material with a releasable adhesive, the foil is then cut, such as by a laser to define the antenna pattern and a removable portion. The removable portion is then manually stripped away, and a strap is then attached with adhesive to the antenna. A small square of hot melt over-laminate may be placed over the strap and bonded, and then a top layer of fabric is added and secured with an adhesive from a transfer tape.