RFID Yarn Module With Multilayer Wash Protection
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Solution Overview
Problem
Conventional RFID tags are not waterproof, easily damaged by washing, and cause environmental issues due to their disposability, with limited operating environments and durability issues.
Innovation Solution
An RFID yarn module is developed with a minimized antenna layout and protected by multiple layers, including a polymer substrate, metal layer, adhesive layers, and protection layers, manufactured using a roll-to-roll process, ensuring durability through washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional RFID tags are made from polymer materials (silicon gel, ABS, PVC, PETG, PC, PP), then the manufacturing cost is reduced and ease of manufacture is improved, but the durability under washing conditions deteriorates and the tags become easily damaged
Solution Approach 1:
The patent uses a composite structure combining flexible printed circuit board (FPC) antenna, RFID element, and multiple protective layers (adhesive layer, protective layer, and yarn-woven fabric). This composite construction provides both manufacturability and washing durability, resolving the contradiction between ease of manufacture and reliability under washing conditions.
2Device complexity
If RFID tags are made disposable (sticker type or hang type), then the device complexity is reduced and ease of manufacture is improved, but environmental harm increases and the tags are easily eliminated or misplaced
Solution Approach 1:
The patent enables the RFID tag to be washed and reused multiple times through its protective construction, transforming the disposable nature of conventional tags into a reusable product. This reduces environmental waste while maintaining simple tag structure, resolving the contradiction between device complexity and environmental harm.
3Ease of manufacture
If the RFID tag structure is simplified for disposable use, then the manufacturing process is simplified, but the protection against static electricity, metal environment, and water deteriorates
Solution Approach 1:
The patent employs a composite structure with FPC antenna, RFID element, adhesive layer, protective layer, and yarn-woven fabric that provides comprehensive protection against static electricity, metal environment, and water while maintaining a relatively simple manufacturing process. This resolves the contradiction between ease of manufacture and protection against harmful factors.
4Adaptability or versatility
If conventional RFID tags are wrapped by yarn-woven fabric, then the flexibility and concealability are improved, but the waterproof performance deteriorates and the RFID element is damaged after washing
Solution Approach 1:
The patent combines yarn-woven fabric with multiple protective layers (adhesive layer and protective layer) to create a composite structure that maintains flexibility and concealability while providing waterproof performance and washing durability. This resolves the contradiction between adaptability and reliability under washing conditions.
Data Source
AI summary
The present invention provides an RFID yarn module comprising a polymer substrate having a first surface and a second surface opposite to the first surface, a metal layer, and a first adhesive layer formed on the metal layer, and a first polymer material layer formed on the first the adhesive layer, a second adhesive layer, and a first protection layer. The metal layer is formed on the first surface of the polymer substrate and has an RFID element electrically connected to the metal layer. The second adhesive layer is formed on the first polymer material layer and is corresponding to the RFID element. The first protection layer is formed on the second adhesive layer. Alternatively, the present invention provides a method for making the RFID yarn module in which a roll-to-roll process for mass manufacturing is utilized to make the RFID yarn module.