Flexible Transponder with Non-Woven Foil Support

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing contactless transponder production methods face challenges in achieving flexibility while maintaining mechanical stability and stress resistance, often requiring additional lamination steps that increase costs and compromise surface quality.

Innovation Solution

A multi-layer laminate support structure incorporating a thin and porous non-woven foil between thermoplastic layers enhances flexibility and stress resistance, allowing for easier lamination and reduced shrinkage, with the non-woven foil being almost invisible after lamination and providing reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If smoother plastic materials such as polyurethane or polyethylene terephthalate glycol are used to produce thinner transponders, then flexibility is improved, but stress resistance and mechanical solidity are weakened

Engineering Contradiction:

ImprovethicknessVSAvoidstress resistance

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining thermoplastic layers with a non-woven support layer to create a multi-layer laminate structure. This composite construction allows the transponder to achieve both flexibility (from the thin thermoplastic layers) and mechanical strength (from the non-woven support layer), resolving the contradiction between thinness and stress resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses thin thermoplastic layers (0.05-0.5 mm) as flexible shell structures that provide the necessary flexibility while being reinforced by the non-woven support layer. This approach enables the transponder to be thin and flexible yet maintain adequate mechanical strength through the combined structure

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If non-woven material foils are inserted in the laminated structure to improve flexibility, then ease of manufacture is improved, but adhesion quality deteriorates due to porosity requirements for plastic penetration

Engineering Contradiction:

ImproveflexibilityVSAvoidadhesion quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the parameters of the non-woven support layer, specifically using a very thin layer (5-50 µm) with controlled porosity. This parameter optimization allows the plastic material to penetrate sufficiently for adhesion while maintaining the flexibility benefits of the non-woven structure, resolving the contradiction between ease of manufacture and adhesion quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by positioning the non-woven support layer specifically between the thermoplastic layers where flexibility is needed, while the thermoplastic layers themselves provide the adhesion surfaces. This localized application of different material properties resolves the contradiction between flexibility and adhesion quality

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If additional lamination steps are performed to improve surface quality, then appearance quality is improved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvesurface qualityVSAvoidnumber of lamination steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the support function and the surface quality function into a single integrated structure. The thermoplastic layers serve dual purposes: providing structural integrity and delivering the required surface quality for printing and appearance, eliminating the need for separate additional lamination steps and reducing manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

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 solution results in a flexible and robust transponder with minimal shrinkage, enabling high-temperature lamination without mechanical stress, and preventing deformation, thus improving manufacturing efficiency and product integrity.

Implementation Method 1

said first and second foils (2, 2') being thermoplastic layers

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

at least one non-woven foil (3) with a grammage of less than 25 g/m2 positioned in direct proximity of at least one of the thermoplastic layers (2, 2')

Methodology Applied

Scientific EffectMechanical reinforcement:

Data Source

PatentUS8946099B2Transponder embedded in a flexible multilayer support

Publication Date: 2015.02.03 HID GLOBAL GMBH

AI summary

The transponder with an electronic unit comprising an antenna coil (4) connected to a chip module (5) embedded in a multi-layer laminate support (1) comprises at least one flexible thermoplastic layer (2) disposed on both sides of the electronic unit wherein the multi-layer laminate support further comprises a non-woven foil (3) with a grammage of less than 25 g/m2.