RFID manufacturing concepts

• US 7,014,729 B2
• Filed: 07/29/2002
• Issued: 03/21/2006
• Est. Priority Date: 02/18/2000
• Status: Expired due to Term

• Current Assignee: Moore Wallace North America Incorporated (RR Donnelley & Sons Company)
• Original Assignee: Moore Wallace North America Incorporated (RR Donnelley & Sons Company)
• Inventors: Soltysiak, John R., Nash, Thomas P., Shipston, Adele C., Mitchell, Nancy G., Grabau, Robert E., Palmer, Eric V.
• Primary Examiner(s): Yao, Sam Chuan
• Assistant Examiner(s): Musser, Barbara J.
• Application Number:
  US10/206,041
• Publication Number:
  US 20020195194A1
• Time in Patent Office: 1,331 Days
• Field of Search: 156/290, 156/291, 156/299, 156/300, 156/301, 156/302
• US Class Current: 156/290
• CPC Class Codes: B31D 1/021 Making adhesive labels having a multilayered structure, e.g. provided on carrier webs
• CPC Class Codes: B31D 1/027 involving, marking, printing or coding
• CPC Class Codes: B31D 1/028 Applying RFID chips
• CPC Class Codes: G06K 17/0025 the arrangement consisting of a wireless interrogation device in combination with a device for optically marking the record carrier
• CPC Class Codes: G06K 19/07718 the record carrier being manufactured in a continuous process, e.g. using endless rolls
• CPC Class Codes: G06K 19/07749 the record carrier being capable of non-contact communication, e.g. constructional details of the antenna of a non-contact smart card
• CPC Class Codes: G06K 19/0776 the adhering arrangement being a layer of adhesive, so that the record carrier can function as a sticker
• CPC Class Codes: Y10T 156/1093 with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 156/1095 Opposed laminae are running length webs
• CPC Class Codes: Y10T 156/1097 Lamina is running length web
• CPC Class Codes: Y10T 156/1741 Progressive continuous bonding press [e.g., roll couples]
• CPC Class Codes: Y10T 29/5317 Laminated device
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1471 Protective layer
• CPC Class Codes: Y10T 428/1486 Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/28 Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2848 Three or more layers

Abstract

Radio frequency identification labels are made in a high speed and effective manner in a variety of different ways utilizing a number of different sources of RFID inlets, each inlet including an antenna and a chip. A plurality of webs are matched together and RFID labels are die cut from the webs, to produce lined RFID labels. Alternatively linerless RFID labels are produced from a composite web with a release material on one face and pressure sensitive adhesive on the other, the labels formed by perforations in the web.

Claims

1. A method of making RFID labels, comprising:

(a) providing a plurality of RFID inlets, each including a chip, on a first web;

(b) covering the RFID inlets with a second web, to form a composite web;

(c) laminating a third web onto the composite web by passing the webs between laminating rolls to sandwich the inlets between the second and third webs without harming the inlets, by providing a recess in at least one of the laminating rolls in alignment with the inlets;

(d) providing pressure sensitive adhesive on a portion of one of the webs that will be an exterior portion of a label once ultimately formed; and

(e) acting on the composite web so as to form the composite web into labels having a top face, and a bottom face with pressure sensitive adhesive.

2. A method as recited in claim 1 wherein (c) is practiced by providing a deformable covering on at least one of the laminating rolls so that the deformable covering deforms when contacting the inlets.

3. A method as recited in claim 1 wherein (e) is practiced by die cutting the labels from composite web to provide a plurality of labels and matrix material on a liner, and removing the matrix material from the labels on the liner.

4. A method as recited in claim 1 further comprising applying heat expandable microspheres on the chips, and heating the microspheres to expand the microspheres to produce a cushion.

5. A method as recited in claim 1 further comprising, before (b) and (c), separating a label laminate into a face web and a liner web, and then using one of the face web and liner web as the second web and the other as the third web.

6. A method as recited in claim 1 wherein (a) is practiced by using an RFID film;

and further comprising cutting the film into individual sheets, each containing an RFID inlet, and wherein (b) and (c) are practiced by placing the individual sheets onto the second web.

7. A method as recited in claim 1 wherein (a)–

(e) are practiced at a rate of at least about 100 ft./min.