Low-profile real-time location system tag

• US 9,626,616 B2
• Filed: 06/05/2015
• Issued: 04/18/2017
• Est. Priority Date: 06/05/2014
• Status: Active Grant

• Current Assignee: Zebra Technologies Corporation
• Original Assignee: ZIH Corp. (Zebra Technologies Corporation)
• Inventors: Richley, Edward A.
• Primary Examiner(s): Haupt, Kristy A
• Application Number:
  US14/732,126
• Publication Number:
  US 20150379387A1
• Time in Patent Office: 683 Days
• CPC Class Codes: G06K 19/0702 the arrangement including a battery
• CPC Class Codes: G06K 19/0704 the battery being rechargeable, e.g. solar batteries
• CPC Class Codes: G06K 19/0717 the sensor being capable of sensing environmental conditions such as temperature history or pressure
• CPC Class Codes: G06K 19/0723 the record carrier comprising an arrangement for non-contact communication, e.g. wireless communication circuits on transponder cards, non-contact smart cards or RFIDs
• CPC Class Codes: G06K 19/0772 Physical layout of the record carrier
• CPC Class Codes: G06K 19/07728 the record carrier comprising means for protection against impact or bending, e.g. protective shells or stress-absorbing layers around the integrated circuit
• 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 19/07773 Antenna details antennas for wireless devices, e.g. RFID tags, in general H01Q1/22
• CPC Class Codes: H01Q 1/2225 used in active tags, i.e. provided with its own power source or in passive tags, i.e. deriving power from RF signal
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142

Abstract

Embodiments of the present invention provide methods for an electrical-mechanical interface associated with a miniature RTLS tag, wherein a mechanical shock absorption comprises a protective antenna enclosure and a potting material to secure the electronics to printed circuit boards. A polyester cup seal prevents the potting material from interacting electrically with an RF antenna. A signal processor is electrically isolated from the antenna by a RF shield or metal can. The cup seal is vacuum-sealed about the RF shield. Flexibility in radiation patterns for the antenna is made possible by eliminating the electrical interactions of the dielectric materials associated with mechanical shock absorption and the antenna. The antenna is approximately circular, with a coaxial center feed through the antenna aperture, and is perturbed by purposeful metal and dielectric adjustments to generate nearly omni-directional radiation patterns in elevation and azimuth.

Claims

1. A miniature and impact resistant real-time location system tag comprising:

a signal processor configured to generate blink data, the blink data comprising a series of ultra wide band pulses and data;

a dielectric antenna support defining an antenna cavity;

a compact high bandwidth antenna seated within the antenna cavity and disposed in electrical communication with the signal processor, the antenna configured to transmit the blink data;

a radio frequency shield configured to prevent parasitic radiation affecting antenna transmissions;

a mechanical isolator configured to protect a printed circuit board device; and

a cup seal configured to prevent the mechanical isolator from entering the radio frequency shield, wherein the mechanical isolator comprises a potting material.

2. The miniature and impact resistant real-time location system tag of claim 1 wherein the radio frequency shield is structured to cover transmitter electronics associated with a printed circuit board.

3. The miniature and impact resistant real-time location system tag of claim 1 wherein the potting material is configured to affix a tag assembly within a protective housing.

4. The miniature and impact resistant real-time location system of claim 3, wherein the protective housing is structured as an oblong protective housing configured to house an oblong tag assembly, the oblong tag assembly comprising an oblong printed circuit board and the compact high bandwidth antenna.

5. The miniature and impact resistant real-time location system tag of claim 1 wherein the cup seal is structured to control a flow of the potting material.

6. The miniature and impact resistant real-time location system of claim 1, wherein the cup seal seals to a printed circuit board over the radio frequency shield.

7. A method for fabricating a miniature and impact resistant real-time location system tag, comprising:

sealing a cup seal to at least one printed circuit board, the cup seal structured to be sealed over a radio frequency shield and to prevent potting material from entering the radio frequency shield, wherein the at least one printed circuit board is associated with a signal processor, transmitter electronics, and an antenna;

encasing a tag assembly comprising the at least one printed circuit board and the antenna within a shock absorbing material;

depositing the potting material to secure the tag assembly within the shock absorbing material; and

tuning the antenna, whereby the tuning is unaffected by the sealing, the encasing, or the depositing.

8. The method for fabricating a miniature and impact resistant real-time location system tag of claim 7 wherein the shock absorbing material comprises a hard, tough housing.

9. The method for fabricating a miniature and impact resistant real-time location system tag of claim 8 wherein the plastic can absorb a shock greater than 100-200 g'"'"'s.

10. The method for fabricating a miniature and impact resistant real-time location system tag of claim 7 wherein the radio frequency shield comprises a metal can structured to cover at least the transmitter electronics.

11. The method for fabricating a miniature and impact resistant real-time location system tag of claim 7 wherein the sealing, the encasing, and the depositing results in a predictable distribution of dielectric mechanical and electrical isolators which do not effect a change in a radiation pattern of the antenna.

12. The method for fabricating a miniature and impact resistant real-time location system tag of claim 7 wherein the radio frequency shield is structured to shield the antenna from parasitic radio frequency radiation generated by the transmitter electronics.

13. A miniature and impact resistant real-time location system location tag comprising:

a signal processor configured to generate blink data, the blink data comprising a series of ultra wide band pulses and data;

a compact high bandwidth antenna configured to transmit the blink data in association with transmitter electronics;

a radio frequency shield structured to prevent parasitic radiation from affecting antenna transmissions;

at least one printed circuit board, wherein the at least one printed circuit board is associated with a signal processor and the antenna, wherein the at least one printed circuit board and the antenna comprise a tag assembly;

a cup seal sealed around the radio frequency shield to prevent potting material from entering the radio frequency shield; and

a shock absorbing material encasing the tag assembly wherein the potting material secures the tag assembly within the shock absorbing material.

14. The miniature and impact resistant real-time location system tag of claim 13 wherein the shock absorbing material comprises a hard, tough protective housing.

15. The miniature and impact resistant real-time location system tag of claim 14 wherein the protective housing can absorb a shock greater than 100-200 g'"'"'s.

16. The miniature and impact resistant real-time location system tag of claim 14, wherein the protective housing is structured as an oblong protective housing configured to house an oblong tag assembly, the oblong tag assembly comprising an oblong printed circuit board and the compact high bandwidth antenna.

17. The miniature and impact resistant real-time location system tag of claim 13 wherein the radio frequency shield comprises a metal can form-fitted to cover at least the transmitter electronics.

18. The miniature and impact resistant real-time location system tag of claim 13 wherein sealing the cup seal around the radio frequency shield comprises sealing the cup seal to the at least one printed circuit board.

19. The miniature and impact resistant real-time location system tag of claim 13 wherein the cup seal, the shock absorbing material, and the potting material provide a predictable distribution of dielectric mechanical and electrical isolators which do not effect a change in a radiation pattern of the compact high bandwidth antenna.

20. A miniature and impact resistant real-time location system location tag comprising:

at least one printed circuit board comprising a signal processor and transmitter electronics;

the signal processor configured to generate blink data, the blink data comprising a series of ultra wide band pulses and data;

a compact high bandwidth antenna configured to transmit the blink data in association with the transmitter electronics, wherein the compact high bandwidth antenna is associated with the at least one printed circuit board;

wherein the compact high bandwidth antenna and the at least one printed circuit board comprise a tag assembly;

a shock absorbing housing encasing the tag assembly; and

a cup seal structured to seal over the transmitter electronics comprised on a top layer of the at least one printed circuit board to prevent potting material from affecting the transmitter electronics.

21. The miniature and impact resistant real-time location system tag of claim 20, t comprising potting material structured to secure the tag assembly within the shock absorbing housing.

22. The miniature and impact resistant real-time location system tag of claim 20, wherein the at least one printed circuit board comprises a plurality of printed circuit board layers and the transmitter electronics comprises a filter, the filter being embedded within the plurality of printed circuit board layers to prevent parasitic radiation from affecting an antenna radiation pattern.

23. The miniature and impact resistant real-time location system tag of claim 22, further comprising a plurality of printed circuit board planes embedded in one or more of the plurality of printed circuit board layers to further prevent parasitic radiation from affecting the antenna radiation pattern.

24. The miniature and impact resistant real-time location system tag of claim 20, wherein the tag assembly comprises a circular tag assembly structured to improve an antenna radiation pattern produced by the miniature and impact resistant real-time location system tag.

25. The miniature and impact resistant real-time location system tag of claim 24, wherein the improvement to the antenna radiation pattern comprises producing a more uniform antenna radiation pattern.

26. The miniature and impact resistant real-time location system tag of claim 20, the cup seal being structured to seal over an antenna aperture defined by the at least one printed circuit board.

27. The miniature and impact resistant real-time location system tag of claim 24, wherein the shock absorbing housing is structured as a circular protective housing configured to house the circular tag assembly.

28. A miniature and impact resistant real-time location system location tag comprising:

at least one printed circuit board comprising a signal processor and transmitter electronics, wherein the at least one printed circuit board comprises a plurality of printed circuit board layers and the transmitter electronics comprises a filter, the filter being embedded within the plurality of printed circuit board layers to prevent parasitic radiation from affecting an antenna radiation pattern;

a plurality of printed circuit board planes embedded in one or more of the plurality of printed circuit board layers to further prevent parasitic radiation from affecting the antenna radiation pattern;

the signal processor configured to generate blink data, the blink data comprising a series of ultra wide band pulses and data;

a compact high bandwidth antenna configured to transmit the blink data in association with the transmitter electronics, wherein the compact high bandwidth antenna is associated with the at least one printed circuit board;

wherein the compact high bandwidth antenna and the at least one printed circuit board comprise a tag assembly; and

a shock absorbing housing encasing the tag assembly.