Trench Roller Transfer of Flexible Conductor Wire
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Solution Overview
Problem
Existing methods for attaching flexible conductors to RFID tags on fabric materials often damage the fabric due to high pressures and temperatures used in the process, which are necessary for secure attachment.
Innovation Solution
A system and method involving a roller with a circumferential trench for depositing and shaping a flexible conductor wire, which is then transferred onto a moving web of material using a wire dispenser head, with options for adhesives or mechanical fasteners for secure attachment, allowing for gentle and effective transfer without fabric damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressures and temperatures are used to securely attach flexible conductors to RFID devices and fabric items, then the attachment strength is improved, but the fabric material is damaged
Solution Approach 1:
The attachment process is segmented into two distinct stages: first, the conductor is securely attached to the RFID device using high pressure and temperature in a controlled environment; second, the assembled unit is attached to the fabric item using a gentler process. This segmentation allows the harsh conditions to be isolated to where they are needed (conductor-RFID attachment) without affecting the fabric
Solution Approach 2:
The RFID device serves as an intermediary component between the conductor and the fabric item. The conductor is first attached to the RFID device, creating a pre-assembled unit that is then attached to the fabric. This intermediary approach allows the conductor-RFID bond to be formed under optimal high-pressure/temperature conditions while the fabric interaction occurs under gentler conditions
Data Source
AI summary
A roller features a circumferential trench into which a wire is deposited from a wire dispensing head having a wire dispensing tip. A moving web of material engages the roller as the roller rotates. The wire dispensing tip engages sidewalls of the trench so that the wire dispensing tip remains in the trench as the roller rotates. Wire from the trench is deposited onto the web of moving material and is secured thereto by fasteners or tape or adhesive or the like.