RFID Tag Attachment via Curable Adhesive Void
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Solution Overview
Problem
The current methods for attaching identification tags to surgical tools are time-consuming, expensive, and require skilled technicians, and they do not ensure error-free tracking, which increases the risk of surgical items being left inside patients and poses compliance challenges with regulatory requirements.
Innovation Solution
An identification tag formed with an electronic circuit embedded in a curable material enclosure, where three layers of curable material are used to create a robust and adhesive attachment system, ensuring a distance of at least 0.5 mm between the tag and the item to prevent interference, allowing for easy and durable attachment by non-skilled workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to attach identification tags to surgical tools, then the attachment reliability is improved, but the complexity of the attachment process and the skill level required increase
Solution Approach 1:
The patent replaces the mechanical/thermal laser welding process with a chemical adhesive bonding system. The adhesive composition cures to form a strong bond between the tag and tool, eliminating the need for complex welding equipment and skilled operators while maintaining attachment reliability.
Solution Approach 2:
The patent changes the bonding mechanism from thermal (laser welding) to chemical (adhesive curing). This parameter change allows for simpler attachment processes that do not require high energy input or specialized skills, while still achieving reliable and durable tag attachment to surgical tools.
2Strength
If laser welding is used to attach identification tags, then the attachment strength is improved, but the time required for attachment and cost increase
Solution Approach 1:
The patent substitutes the time-consuming laser welding process with a faster adhesive application and curing process. The adhesive can be applied quickly and cures to provide strong bonding, significantly reducing the time required for tag attachment compared to welding operations.
Solution Approach 2:
The patent employs a disposable adhesive composition that is applied in a simple, rapid process. This eliminates the need for expensive, time-consuming welding operations and skilled technicians, reducing both attachment time and cost while maintaining sufficient attachment strength for surgical tool identification.
3Measurement precision
If manual counting of surgical items is performed, then the tracking accuracy is improved, but the resource consumption and time required increase
Solution Approach 1:
The patent implements self-service tracking through RFID tags that automatically provide identification and tracking information. The electronic circuits in the tags enable automated detection and tracking of surgical tools, eliminating the need for manual counting by personnel while maintaining accurate tracking records.
Solution Approach 2:
The patent replaces manual counting operations with automated electronic tracking systems. RFID readers and electronic circuits automatically detect, identify, and track surgical tools throughout the surgical process, providing accurate tracking information without requiring personnel time or mental resources for manual counting.
4Reliability
If identification tags are attached to surgical tools, then the tracking capability is improved, but the risk of tag damage from heating increases
Solution Approach 1:
The patent replaces thermal attachment methods (laser welding) that can damage tags with a chemical adhesive bonding system. The adhesive curing process does not generate excessive heat, thereby protecting the electronic circuits and antenna in the RFID tags from thermal damage while maintaining reliable tracking capability.
Solution Approach 2:
The patent introduces an adhesive composition as an intermediary between the tag and the surgical tool. This adhesive layer provides a thermal barrier during any heating processes and ensures secure attachment without directly exposing the tag to harmful heat, thereby protecting tag integrity while enabling reliable tracking.
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 solution simplifies and accelerates the attachment process, reduces the need for skilled labor, and ensures reliable tracking of surgical items, enhancing compliance with regulatory requirements and reducing the risk of items being left inside patients.
Implementation Method 1
A base that serves as a container is cast from the curable material (e.g. using a mold); The electronic circuit is placed in the base; A second layer of curable material is used to fill around the electronic circuit to make a robust enclosure and to form a protective layer over the electronic circuit; wherein a void is left in the base above the protective layer over the electronic circuit; The robust enclosure is attached to the item by injecting a third layer of curable material in the void and curing it while in contact with the item
Implementation Method 2
The electronic circuit is designed to provide a unique ID in response to a wireless query in the form of an electromagnetic signal
Implementation Method 3
The robust enclosure is attached to the item by injecting a third layer of curable material in the void and curing it while in contact with the item
Data Source
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AI summary
An identification tag that is attachable to an item and serves to identify the item with a computerized system, including a base in the form of a container that is cast from a curable material, an electronic circuit that is placed in the base and wirelessly provides a unique ID in response to an electromagnetic signal, a second layer of the curable material filling the base and forming a protective cover over the electronic circuit; and wherein a void of at least 0.5mm is formed in the base above the second layer; wherein the void is designed to receive a third layer of the curable material for adhesively attaching the identification tag to the item leaving a distance of more than 0.5mm between the electronic circuit and the item.