Flexible Web Assembly for RFID Tags with Pitch Mismatch

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high cost and complexity of manufacturing RFID tags stem from the difficulty in aligning and assembling components with different pitches on substrates, particularly antennas and straps, which hinders high-speed production.

Innovation Solution

The method involves displacing one substrate web out of its plane to match the pitch of components on another substrate web, allowing for precise alignment and assembly of articles with different spacings, using techniques like negative or positive pressure to adjust the web's position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If articles are arranged on substrates with different pitches to accommodate different component sizes, then component layout flexibility is improved, but alignment precision deteriorates

Engineering Contradiction:

Improvecomponent layout flexibilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent introduces a temporal dimension to the alignment process by sequentially positioning articles from different substrates at different pitches. Instead of requiring simultaneous alignment in space, the system accommodates different pitches by controlling the timing and sequence of article delivery, transforming a spatial alignment problem into a temporal coordination problem.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The assembly system dynamically adjusts the delivery speed and timing of articles from different substrates. By making the article delivery process dynamic and adaptable rather than static and fixed, the system can accommodate varying pitches while maintaining precise alignment at the assembly point through real-time speed modulation.

Inventive Principle:

Principle #15Dynamics

2Productivity

If assembly speed is increased to improve productivity, then production efficiency is improved, but alignment accuracy deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoidalignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary positioning and speed adjustments before the actual assembly point is reached. Articles are pre-coordinated in their delivery timing and speed, allowing high-speed operation while maintaining alignment accuracy through advance preparation rather than last-minute adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates feedback mechanisms that continuously monitor the position and speed of articles from different substrates, enabling real-time corrections to maintain alignment accuracy even at high assembly speeds. This closed-loop control ensures precision is preserved despite increased production velocity.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If sophisticated equipment is used to register arrays at different pitches, then alignment capability is improved, but device complexity increases

Engineering Contradiction:

Improvealignment capabilityVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of using complex mechanical registration equipment, the system changes the operational parameters of the existing substrates - specifically their delivery speeds and timing. By adjusting these controllable parameters, the system achieves alignment capability without introducing additional complex mechanical devices.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces sophisticated mechanical registration equipment with a control-based system that uses speed and timing adjustments. This substitution eliminates complex mechanical registration mechanisms in favor of a more simple electronic or programmable control system that achieves the same alignment function through parameter modulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 simplifies and economizes the assembly process, enabling high-speed production of RFID tags by facilitating accurate registration and connection of components with reduced equipment complexity.

Implementation Method 1

displacing portions of the first substrate between adjacent first elements out of the plane of the first substrate to thereby draw adjacent first elements closer to one another

Methodology Applied

Scientific EffectNegative pressure: Suction

Implementation Method 2

applying negative pressure to portions of the first substrate in order to draw out portions of the plane

Methodology Applied

Scientific EffectPositive pressure: Pressure Increase

Data Source

PatentUS11301739B2Method of assembly of articles and intermediate created thereby

Publication Date: 2022.04.12 AVERY DENNISON RETAIL INFORMATION SERVICES LLC

AI summary

Articles on flexible webs with different pitches are assembled together by displacing portions between articles of one web out of plane to move the articles on that web to the same pitch as the other web, aligning the two webs to register corresponding articles on the two webs, and assembling the corresponding articles together. The assembly may be used for example in the making of RFID tags, labels and inlays.