Methods and systems for in-line RFID transponder assembly

• US 7,651,032 B2
• Filed: 06/22/2005
• Issued: 01/26/2010
• Est. Priority Date: 06/22/2005
• Status: Expired due to Fees

• Current Assignee: WestRock Shared Services, LLC (WestRock Company)
• Original Assignee: Smurfit-Stone Container Enterprises Incorporated (WestRock Company)
• Inventors: Shanton, Kenneth
• Primary Examiner(s): Lee; Michael G
• Assistant Examiner(s): Haupt; Kristy A
• Application Number:
  US11/158,704
• Publication Number:
  US 20060290513A1
• Time in Patent Office: 1,679 Days
• Field of Search: 235/472.02, 235/491, 235/492, 354/720.2
• US Class Current: 235/491
• 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 19/07752 using an interposer
• CPC Class Codes: Y10T 156/1016 Transverse corrugating

Abstract

Methods and apparatus for manufacturing a radio frequency identification (RFID) enabled corrugated paperboard are provided. The apparatus includes a corrugated paperboard feed device configured to supply a quantity of corrugated paperboard, an antenna attach device configured to couple an antenna to the corrugated paperboard, a curing device configured to provide curing energy to the antenna to at least one of dry the antenna and facilitate optimizing an electrical conductivity of the antenna, and an attach mechanism configured to couple a radio frequency identification circuit to the antenna.

Claims

1. An apparatus for manufacturing a radio frequency identification (RFID) enabled corrugated paperboard used for forming a container, said container comprising an interior surface defining an enclosed volume and an exterior surface defining an external periphery of the container, said apparatus comprising:

a corrugated paperboard feed device configured to supply a quantity of corrugated paperboard, the corrugated paperboard used for forming the container;

an antenna attach device configured to couple an antenna to an outer surface of the finished corrugated paperboard wherein when finished, the corrugated paperboard includes a linerboard and a corrugated medium, said antenna attach device is configured to couple the antenna to the linerboard on a side opposite the corrugated medium in a position that is configured to be the exterior surface of the container;

a curing device configured to provide curing energy to said antenna to at least one of dry said antenna and facilitate optimizing an electrical conductivity of said antenna; and

an attach mechanism configured to couple a radio frequency identification circuit to each said antenna on the outer surface of the finished corrugated paperboard in a position on the external surface of the container.

2. An apparatus in accordance with claim 1 wherein said antenna attach device comprises a press configured to couple said antenna to the corrugated paperboard using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process.

3. An assembly line for manufacturing radio frequency identification enabled corrugated paperboard comprising:

a supply of corrugated paperboard, the corrugated paperboard used for forming a container comprising an interior surface defining an enclosed volume and an exterior surface defining an external periphery of the container;

a press configured to couple an antenna to an outer surface of said supply of corrugated paperboard in a position that is configured to be the exterior surface of the container wherein when finished, the corrugated paperboard includes a linerboard and a corrugated medium, said press is configured to couple the antenna to the linerboard on a side opposite the corrugated medium, said antenna comprising a connection area and at least one receiving area;

a curer configured to provide curing energy to said antenna;

a sensor configured to locate a connection area of each of said plurality of antennae; and

an attach mechanism configured to couple a radio frequency identification circuit to each said connection area.

4. A assembly line in accordance with claim 3 wherein said press is configured to print said plurality of antennae using a conductive ink comprising at least one of copper, aluminum, silver, and organic conducting polymers.

5. A assembly line in accordance with claim 3 wherein said press is configured to print said plurality of antennae using at least one of a plurality of layers of conductive ink, and a plurality of conductive ink layers and dielectric layers.

6. A assembly line in accordance with claim 3 wherein said press is configured to couple said plurality of antennae to said surface using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process.

7. An assembly line in accordance with claim 3 wherein said curer comprises an illuminator configured to direct radiation to cure said antenna.

8. An assembly line in accordance with claim 3 wherein said curer comprises a heating element configured to heat said antenna to cure said antenna.

9. A method of forming a radio frequency identification (RFID) enabled corrugated paperboard, said method comprising:

providing a quantity of corrugated paperboard, the corrugated paperboard used for forming a container comprising an interior surface defining an enclosed volume and an exterior surface defining an external periphery of the container;

coupling at least one antennae to an outer surface of the corrugated paperboard in a position that is configured to be the exterior surface of the container wherein when finished, the corrugated paperboard includes a linerboard and a corrugated medium, and wherein coupling comprises coupling the at least one antenna to the linerboard on a side opposite the corrugated medium, the at least one antennae comprising a connection area and at least one receiving area;

curing the at least one antennae using at least one of heat and radiation;

optically locating the connection area of the antenna; and

coupling a radio frequency identification circuit to the antenna connection area such that radio frequency energy received by the antenna is transmitted to the radio frequency identification circuit.

10. A method in accordance with claim 9 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises printing a primer pattern on the surface of the corrugated paperboard.

11. A method in accordance with claim 10 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises printing a conductive ink antenna over at least a potion of the primer pattern.

12. A method in accordance with claim 10 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises printing a conductive ink antenna over substantially all of the primer pattern.

13. A method in accordance with claim 9 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises coupling at least one antennae to a surface of the corrugated paperboard using a conductive ink.

14. A method in accordance with claim 13 wherein coupling at least one antennae to a surface of the corrugated paperboard using a conductive ink comprises printing the at least one antenna using a conductive ink that includes at least one of copper, aluminum, silver, and organic conducting polymers.

15. A method in accordance with claim 14 wherein printing the at least one antenna using a conductive ink comprises printing the at least one antennae using a plurality of layers of conductive ink.

16. A method in accordance with claim 14 wherein printing the at least one antenna using a conductive ink comprises printing the at least one antennae using a plurality of dielectric layers.

17. A method in accordance with claim 9 wherein coupling at least one antenna to a surface of the corrugated paperboard comprises coupling at least one antenna using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process.

18. A method in accordance with claim 9 wherein curing the at least one antennae comprises illuminating the plurality of antennae using a radiation source.

19. A method in accordance with claim 9 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises pre-printing the plurality of antennae on the corrugated paperboard using an off-line print process.

20. A method in accordance with claim 9 wherein coupling at least one antennae to a surface of the corrugated paperboard comprises applying a heat resistant overprint varnish (OPV) over at least a portion of the antenna such that the connection area is not covered by the OPV.

21. A method in accordance with claim 9 wherein coupling a radio frequency identification circuit to the antenna connection area comprises coupling a radio frequency identification circuit to the antenna connection area downstream from a double facer.

22. A method in accordance with claim 9 wherein coupling a radio frequency identification circuit to each antenna connection area comprises coupling the radio frequency identification circuit directly to a respective antenna connection area, and coupling the radio frequency identification circuit to the antenna connection area using a strap.