Thermoformed apparatus having a communications device

• US 6,943,678 B2
• Filed: 01/24/2001
• Issued: 09/13/2005
• Est. Priority Date: 01/24/2000
• Status: Expired due to Term

• Current Assignee: Nextreme LLC
• Original Assignee: Nextreme LLC
• Inventors: Muirhead, Scott A. W.
• Primary Examiner(s): Pope, Daryl C.
• Application Number:
  US09/770,097
• Publication Number:
  US 20020030597A1
• Time in Patent Office: 1,693 Days
• Field of Search: 340/572.1, 340/572.4, 340/572.8, 340/568.1, 340/10.1, 340/10.3, 340/10.32, 340/10.4, 340/10.51, 340/505, 340/539.13, 156/226, 156/227, 156/290, 705/28, 235/385, 235/383, 235/384
• US Class Current: 340/505
• CPC Class Codes: B29C 2049/24308 comprising electronic elements or detection means, e.g. chips, RFIDs or barcodes
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/157 Coating linked inserts, e.g. chains
• CPC Class Codes: B29C 51/02 Combined thermoforming and manufacture of the preform
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/162 of deep containers or boxes
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 51/46 Measuring, controlling or regulating
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/433 Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/4722 Fixing strips to surfaces other than edge faces fixing strips to edge faces B29C63/0026
• CPC Class Codes: B29C 66/543 joining more than two hollow-preforms to form said hollow articles
• CPC Class Codes: B29C 66/545 one hollow-preform being placed inside the other
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/83411 Roller, cylinder or drum types B29C66/83431 takes precedence; rollers, cylinders or drums moving relative to and tangentially to the parts to be joined B29C66/8362
• CPC Class Codes: B29C 66/96 characterised by the method for implementing the controlling of the joining process
• CPC Class Codes: B29C 66/9672 involving special data inputs, e.g. involving barcodes, RFID tags
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2017/00 : Carriers for sound or information
• CPC Class Codes: B29L 2031/7126 : large, e.g. for bulk storage
• CPC Class Codes: B29L 2031/7172 : Fuel tanks, jerry cans
• CPC Class Codes: B29L 2031/7178 : Pallets
• CPC Class Codes: B65D 19/0018 : and each contact surface having a discrete foot-like shape
• CPC Class Codes: B65D 2203/10 : Transponders
• CPC Class Codes: B65D 2519/00034 : Plastic
• CPC Class Codes: B65D 2519/00069 : Plastic
• CPC Class Codes: B65D 2519/00139 : Plastic
• CPC Class Codes: B65D 2519/00268 : made of one piece
• CPC Class Codes: B65D 2519/00273 : made of more than one piece
• CPC Class Codes: B65D 2519/00288 : made of one piece
• CPC Class Codes: B65D 2519/00318 : made of one piece
• CPC Class Codes: B65D 2519/00338 : contact surface having a discrete foot-like shape
• CPC Class Codes: B65D 2519/00407 : on the load supporting surface
• CPC Class Codes: B65D 2519/00412 : on the base surface
• CPC Class Codes: B65D 2519/00437 : on the load supporting surface
• CPC Class Codes: B65D 2519/00442 : on the base surface
• CPC Class Codes: B65D 2519/00557 : without separate auxiliary elements
• CPC Class Codes: B65D 2519/00562 : chemical connection, e.g. glued, welded, sealed
• CPC Class Codes: B65D 2519/0094 : nestable
• CPC Class Codes: G08B 13/2417 : having a radio frequency identification chip
• CPC Class Codes: G08B 13/2434 : Tag housing and attachment details
• CPC Class Codes: G08B 13/244 : Tag manufacturing, e.g. continuous manufacturing processes
• CPC Class Codes: G08B 13/2445 : Tag integrated into item to be protected, e.g. source tagging
• CPC Class Codes: G08B 13/2462 : Asset location systems combined with EAS inventory, tracking, logistic G06Q10/00; entrance control systems G07C9/00
• CPC Class Codes: Y10S 108/901 : Synthetic plastic industrial platform, e.g. pallet
• CPC Class Codes: Y10T 156/1049 : Folding only
• CPC Class Codes: Y10T 156/1051 : by folding
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 156/109 : Embedding of laminae within face of additional laminae
• CPC Class Codes: Y10T 156/1734 : Means bringing articles into association with web

Abstract

An apparatus has a communications device associated therewith. In another aspect of the present invention, a pallet is made from thermoformed polymeric sheets with an attached communications device. A further aspect of the present invention provides a radio frequency identification device attached to an apparatus. In still another aspect of the present invention, a communications device is incorporated into one or more sheets of a pallet or other container prior to forming. Methods of making and using a thermoformed pallet and container, having a communications device, are also provided.

Claims

1. A system comprising:

a manufacturing machine;

a receiver;

an electrical control system connected to the receiver and the machine;

a product having multiple sheets and a data storage device located between the sheets, the product being manufactured by the machine;

the receiver operably interfacing with the data storage device to ascertain data previously stored on the device, the control system changing manufacturing characteristics of the machine based on a data received from the device.

2. The system of claim 1 wherein the data is ascertained by the receiver from the device prior to manufacturing of the product containing the device by the machine.

3. The system of claim 1 wherein the machine includes a mold operable to three-dimensionally shape the product.

4. The system of claim 1 wherein the machine includes a heater operable to heat the product to ease in forming.

5. The system of claim 1 wherein the machine includes a sheet extruder for making the product prior to attachment of the data storage device.

6. The system of claim 1 wherein the data storage device is a radio frequency identification tag.

7. The system of claim 6 wherein the receiver is an interrogator operable communicating with the radio frequency identification tag.

8. The system of claim 1 wherein the machine three-dimensionally shapes the product which subsequently becomes a pallet.

9. The system of claim 1 wherein the data storage device includes an antenna located entirely inside of the product when in its final manufactured condition.

10. A method of manufacturing a product with machinery, and method comprising:

(a) electrically communicating between the product and the machinery in a wireless manner;

(b) changing an operational characteristic of the machinery prior to processing the product in the machinery, based on the communication of step (a); and

(c) shaping the product with the machinery after step (b).

11. The method of claim 10 wherein the product is a multiple sheet pallet, wherein the sheets are made of a polymeric material.

12. The method of claim 10 further comprising communicating between the product and the machinery by transmitting radio frequencies to identify preprogrammed characteristics of the desired end product to be manufactured.

13. An apparatus comprising:

a pallet having a first RFID tag and a second RFID tag,

said first RFID tag including externally readable data indicative of a first characteristic, and

said second RFID tag including externally readable data indicative of a second characteristic.

14. An apparatus as set forth in claim 13 in which:

said first RFID tag externally readable data includes non-erasable data.

15. An apparatus as set forth in claim 14 in which:

said non-erasable data is indicative of a characteristic that is selected from the group consisting of manufacture date, serial number, load bearing strength specification, operating temperature, material composition, repair instruction, expiration date, recycling instructions, pallet ownership, and ISO certificate.

16. An apparatus as set forth in claim 13 in which:

said first RFID tag externally readable data is permanently stored in non-volatile tag memory.

17. An apparatus as set forth in claim 13 which:

said first RFID tag includes a passive tag.

18. An apparatus as set forth in claim 13 in which:

said second RFID tag externally readable data includes data indicative of the location of the pallet.

19. An apparatus as set forth in claim 18 which:

said data indicative of the location of the pallet includes data that is selected from the group consisting of an electronic manifest, a time record, a shipping address, and a bill accounting for the use of said pallet.

20. An apparatus as set forth in claim 13 in which:

said second RFID tag externally readable data includes data indicative of the external environment of the pallet.

21. An apparatus as set forth in claim 13 in which:

said second RFID tag externally readable data includes data indicative of a characteristic of a part transported by the pallet.

22. An apparatus as set forth in claim 13 in which:

said second RFID tag includes a passive tag.

23. An apparatus as set forth in claim 13 in which:

said second RFID tag includes an active tag.

24. An apparatus as set forth in claim 13 in which:

said pallet includes a third RFID tag including externally readable data indicative of a third characteristic.

25. An apparatus as set forth in claim 24 in which:

said pallet includes a fourth RFID tag including externally readable data indicative of a fourth characteristic.

26. An apparatus as set forth in claim 13 which includes:

said first RFID tag being operable in a first RF environment,

said second RFID tag being operable in a second RF environment, and

wherein said first RF environment is incompatible with said second RF environment so that said pallet is interoperable between two incompatible RF environments.

27. An apparatus as set forth in claim 13 which includes:

said first RFID tag operates on a first RF frequency,

said second RFID tag operates on a second RF frequency, and

wherein said pallet is interoperable between two RF frequencies.

28. An apparatus as set forth in claim 13 which includes:

said first RFID tag operating in a first proprietary operating environment,

said second RFID tag operating in a second proprietary operating environment, and

wherein said first proprietary operating environment is incompatible with said second proprietary operating environment so that said pallet is interoperable between two incompatible proprietary operating environments.

29. A material handling device comprising:

a first polymeric member,

a second polymeric member attached to said first polymeric member,

a first externally readable RFID tag positioned between said first member and said second member,

said first tag including information indicative of a first characteristic,

a second externally readable RFID tag positioned between said first member and said second member, and

said second tag including information indicative of a second characteristic.

30. A material handling device as set forth in claim 29 which includes:

said first RFID tag being operable in a first RF environment,

said second RFID tag being operable in a second RF environment,

said first RF environment being incompatible with said second RF environment,

said material handling device being interoperable between two incompatible RF environments.

31. A material handling device as set forth in claim 29 in which:

said first RFID tag operates at a first RF frequency, and

said second RFID tag operates at a second RF frequency.

32. A material handling device as set forth in claim 29 in which:

said first RFID tag operates in a first proprietary operating environment, and

aid second RFID tag operates in a second proprietary operating environment.

33. A material handling device as set forth in claim 32 which includes:

said first proprietary operating environment being incompatible with said second proprietary operating environment so that the material handling device is interoperable between two operating environments.

34. A material handling device as set forth in claim 29 which:

said first RFID tag information includes non-erasable information indicative of the material handling device.

35. A material handling device as set forth in claim 34 in which:

said first RFID tag information includes information that is selected from the group consisting of manufacturing date, serial number, part number, material handling device specifications, material handling device material composition, ownership records, and ISO certificates.

36. A material handling device as set froth in claim 29 in which:

said first RFID tag includes a passive tag.

37. A material handling device as set forth in claim 29 in which:

said second RFID tag information includes information indicative of the location of the material handling device.

38. A material handling device as set forth in claim 37 in which:

said second RFID tag information includes information that is selected from the group consisting of an electronic manifest, a time record, a shipping address, and a bill for accounting for the use of the material handling device.

39. A material handling device as set forth in claim 29 in which:

said second RFID tag includes information indicative of the external environment of the material handling device.

40. A material handling device as set forth in claim 29 which includes:

a third externally readable RFID tag positioned between said first member and said second member, and

said third tag including information indicative of a third characteristic.

41. A material handling device as set forth in claim 40 which includes:

a fourth externally readable RFID tag positioned between said first member and said second member, and

said fourth tag including information indicative of a fourth characteristic.

42. A material handling apparatus comprising:

a first externally readable RFID tag,

a second externally readable RFID tag,

said first RFID tag includes non-erasable information pertaining to the material handling apparatus, and

said second RFID tag includes rewritable information pertaining to events associated with the use of the apparatus.

43. A material handling apparatus as set forth in claim 42 in which:

said first RFID tag information includes information intended for use by a material handling apparatus manufacturer, and

said second RFID tag information includes information intended for use by a material handling apparatus user.

44. A material handling apparatus as set forth in claim 43 which includes:

said first RFID tag information being information that is permanently stored in memory before the apparatus enters a material handling workplace.

45. A material handling apparatus as set forth in claim 42 which includes:

a third externally readable RFID tag including information,

a fourth externally readable RFID tag including information, and

said third RFID tag information and said fourth RFID tag information being indicative of characteristics useful to addition material handling apparatus users.

46. A material handling apparatus as set forth in claim 42 which includes:

said second RFID tag information being stored in volatile memory.

47. A method for using a material handling apparatus having an RFID tag comprising the steps of:

(a) moving the material handling apparatus into an interrogation field by means of a carrier,

(b) reading information stored in a memory component of the RFID tag after the moving step, and

(c) activating an indicator after the reading step to instruct an operator of the carrier to move the material handling apparatus out of the interrogation field.

48. A method as set forth in claim 47 which includes:

visually locating the indicator adjacent to the interrogation field, and

using visible light to activate the indicator.

49. A method as set forth in claim 48 which includes:

providing an indicator having a light that is visible to the carrier operator.

50. A method as set forth in claim 47 which includes:

providing an indicator that is located on the carrier.

51. A method as set forth in claim 50 which includes:

positioning the indicator on the carrier so that the indicator is visible to the operator of the carrier.

52. A method as set forth in claim 47 in which the RFID tag includes information which includes:

providing the RFID tag with information stored in a memory component and at least part of the information including instructions for the carrier operator where to position the material handling apparatus within a distribution network after exiting the interrogation field.

53. A method as set forth in claim 52 which includes:

positioning the indicator on the carrier so that the indicator provides the position within a warehouse to move the material handling apparatus.

54. A method for using a material handling apparatus comprising the steps of:

(a) affixing an RFID tag to the apparatus so that the RFID tag transmits information pertaining to the apparatus,

(b) providing a plurality of interrogators capable of receiving information from the RFID tag within a plurality of interrogation fields located within a distribution network,

(c) providing a plurality of local area computers so that each computer is located within an interrogation field and is connected to a host computer,

(d) providing a plurality of visual message delivery devices within the interrogation fields so that each visual message delivery device is connected to at least one of the local area computers and to the host computer,

(e) providing a carrier to move the apparatus within the distribution network,

(f) providing an operator to maneuver the carrier within the distribution network and to observe the devices,

(g) using the carrier to move the apparatus into one off the interrogation fields to allow one of the interrogators to convey the information pertaining to the apparatus contained on the RFID tag to at least one of the local area computers and the host computer, and

(h) therafter one of the local area computers and the host computer activates the device in the interrogation field observed by the operator to instruct the operator to maneuver the carrier and the apparatus out of one of the interrogation fields.

55. A method as set forth in claim 54 which includes:

providing one of the visual message delivery devices with a light that is visible to the operator.

56. A method as set forth in claim 54 which includes:

positioning one of the devices within the interrogation field adjacent to at least one of the interrogators.

57. A method as set forth in claim 54 which includes:

providing one of the visual message delivery devices having the ability to instruct the operator to remain within the interrogation field allowing at least one of the interrogators to receive complete information pertaining to the apparatus.

58. A method as set forth in claim 54 which includes:

providing an interrogation field having a triggering device that senses the carrier,

activating a local area computer to activate the device to instruct the operator to stop the carrier within the interrogation field.

59. A method as set forth in claim 54 which includes:

providing an interrogation field having a triggering device that senses the carrier,

activating one of the local area computers and the host computer to activate the device to instruct the operator to stop the carrier within the interrogation field, and

activating one of the local area computers and the host computer to activate the device to instruct the operator to resume maneuvering the carrier through the interrogation field.

60. A method of using a material handling apparatus comprising:

(a) affixing an RFID tag upon the apparatus for transmitting information pertaining to the apparatus,

(b) providing a plurality of interrogators capable of receiving information from the RFID tag with each of the interrogators being located in one of a plurality of interrogation fields located within a distribution network,

(c) providing a local area computer connected to each one of the interrogators within each interrogation field with the local area computers being connected to a host computer,

(d) providing a carrier to move the apparatus within the distribution network with the carrier including a visual message delivery device being wirelessly connected to at least one of the local area computers and the host computer,

(e) providing an operator to maneuver the carrier within the distribution network to observe the device,

(f) using the carrier to move the apparatus into one of the interrogation fields thereby allowing one of the interrogators to convey the information pertaining to the apparatus contained on the RFID tag to at least one of the local area computers and the host computer, and

(g) thereafter at least one of the local area computers and the host computer activating the device on the carrier observed by the operator to instruct the operator to maneuver the carrier and the apparatus out of one of the interrogation fields.

61. A method as set forth in claim 60 which includes:

positioning an LED light on the console of the carrier so that the LED light is operable to instruct the operator to stop within and proceed through the interrogation field.

62. A method as set forth in claim 60 which includes:

displaying where the operator is to store the apparatus within a warehouse.

63. A method as set forth in claim 60 which includes:

providing the interrogation field with a triggering device that senses the carrier.

64. A method as set forth in claim 60 which includes:

providing the interrogation field having a triggering device that detects the carrier, and

thereafter informing the local area computer that the triggering device detected the carrier.

65. A method as set forth in claim 64 which includes:

activating the device to instruct the operator to stop or proceed through the interrogation field after the local area computer is informed that the triggering device detected the carrier.

66. A method as set forth in claim 64 which includes:

activating the interrogator to receive information pertaining to the apparatus transmitted by the RFID tag after the local area computer is informed that the triggering device detected the carrier.