U.S. patent application number 10/001365 was filed with the patent office on 2003-04-03 for method and apparatus for associating on demand certain selected media and value-adding elements.
Invention is credited to Donato, Daniel F., Hohberger, Clive P., Ream, Matthew R..
Application Number | 20030063001 10/001365 |
Document ID | / |
Family ID | 25515196 |
Filed Date | 2003-04-03 |
United States Patent
Application |
20030063001 |
Kind Code |
A1 |
Hohberger, Clive P. ; et
al. |
April 3, 2003 |
Method and apparatus for associating on demand certain selected
media and value-adding elements
Abstract
A media printer such as, for example, a thermal transfer media
printer is disclosed. In one embodiment, the printer selectively
programs RFID transponders, and then embeds them into conventional
on-demand printed media between the adhesive layer and the release
liner. Selective configuration of each printed media sample by
addition of value-adding elements may be performed independently
for each media sample, under software control during processing of
each media sample format print control program. An add-on mechanism
is disclosed that can be operatively attached to a conventional
media printer. This allows value-adding elements such as RFID
transponder labels to be selectively applied at precise locations
on the printed surface of on-demand printed media in connection
with existing printers.
Inventors: |
Hohberger, Clive P.;
(Glencoe, IL) ; Ream, Matthew R.; (Naperville,
IL) ; Donato, Daniel F.; (Mundelein, IL) |
Correspondence
Address: |
Welsh & Katz, Ltd.
Jeffrey W. Salmon
22nd Floor
120 South Riverside Plaza
Chicago
IL
60606
US
|
Family ID: |
25515196 |
Appl. No.: |
10/001365 |
Filed: |
October 25, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10001365 |
Oct 25, 2001 |
|
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09969114 |
Oct 1, 2001 |
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Current U.S.
Class: |
340/572.1 ;
101/483; 156/378; 209/552 |
Current CPC
Class: |
B65C 9/1803 20130101;
G06K 19/07779 20130101; G06K 19/07786 20130101; B65H 2701/194
20130101; B41J 3/4075 20130101; Y10T 156/1705 20150115; B41J 3/44
20130101; G06K 19/07749 20130101; G06K 17/0025 20130101; B65C
9/1865 20130101; B65C 2009/404 20130101; G06K 19/07783 20130101;
B65C 2009/0003 20130101; B65H 37/002 20130101; G06K 19/07716
20130101; G06K 19/07718 20130101; G06K 19/0776 20130101 |
Class at
Publication: |
340/572.1 ;
156/378; 101/483; 209/552 |
International
Class: |
G08B 013/14 |
Claims
We claim:
1. A media printer, comprising in combination: means for moving a
plurality of media samples from a supply of media samples; means
for printing information on at least selected ones of said media
samples; and means for attaching a value-adding device to only
selected ones, but not all, of said media samples.
2. The media printer of claim 1 wherein said value-adding devices
comprise radio frequency identification transponders.
3. The media printer of claim 2 further comprising means for
determining whether said radio frequency identification
transponders are defective or misprogrammed.
4. The media printer of claim 3 further comprising means for
causing a failure indicia to be printed on a surface of each one of
said media samples to which a defective or misprogrammed radio
frequency identification transponder is attached.
5. The media printer of claim 1 wherein a plurality of value-adding
devices are attached to at least one of said plurality of media
samples.
6. The media printer of claim 1 wherein said media samples are
selected from a group consisting of labels, tickets, tags, and
cards.
7. A media printer, comprising in combination: a media supply and a
media exit; a generally continuous web that operably interconnects
said media supply and said media exit so that a plurality of media
samples are moved from said media supply to said media exit during
operation; a printhead that is mounted in operative relation to
said generally continuous web to print information on selected
portions of a first surface of each one of said media samples; and
an applicator mechanism that is mounted in operative relation to
said generally continuous web to attach a value-adding device to a
second surface of selected ones of said media samples after
information has been printed on the first surface of said selected
ones of said media samples by said printhead.
8. The media printer of claim 7 wherein said value-adding devices
comprise radio frequency identification integrated circuits adopted
to make contact with an antenna structure on said media samples to
form radio frequency identification transponders.
9. The media printer of claim 7 wherein said value-adding devices
comprise radio frequency identification transponders.
10. The media printer of claim 9 further comprising a verification
mechanism that is operably disposed with respect to said generally
continuous web to verify the operability of at least some of said
radio frequency identification transponders.
11. The media printer of claim 10 wherein said verification
mechanism causes failure indicia to be printed on the first surface
of each one of said media samples to which an inoperable radio
frequency identification transponder is attached.
12. The media printer of claim 7 wherein a value-adding device is
attached to less than all of said plurality of said media
samples.
13. The media printer of claim 7 wherein said media samples are
selected from a group consisting of labels, tickets, tags, and
cards.
14. A method for manufacturing a printed media, comprising the
steps of: moving a plurality of media samples from a media supply
to a media exit; printing information on selected media samples;
and attaching a value-adding device to said selected ones of said
media samples after information has been printed on the first
surface of said selected ones of said media samples.
15. The method of claim 14 wherein said value-adding devices
comprise radio frequency identification integrated circuits adopted
to make contact with an antenna structure on said media samples to
form radio frequency identification transponders.
16. The method of claim 14 wherein said value-adding devices
comprise radio frequency identification transponders.
17. The method of claim 14 further comprising the step of verifying
that at least some of said radio frequency identification
transponders are operable.
18. The method of claim 17 further comprising the step of causing
failure indicia to be printed on the first surface of each one of
said media samples to which an inoperable, or misprogrammed radio
frequency identification transponder is attached.
19. The method of claim 14 wherein a value-adding device is
attached to less than all of said plurality of said media
samples.
20. The method of claim 14 wherein said media samples are selected
from a group consisting of labels, tickets, tags, and cards.
21. A device for use in connection with a thermal transfer printer
that includes first web means for moving a plurality of media
samples from a supply of media samples as well as a printhead that
prints information on a first surface of said plurality of media
samples, said device comprising: a second web means for temporarily
removing the plurality of media samples from said first web means;
and means for attaching a value-adding device to a second surface
of selected ones of said media samples after information has been
printed on the first surface of said selected ones of said media
samples.
22. The device of claim 21 wherein said value-adding devices
comprise radio frequency identification integrated circuits adopted
to make contact with an antenna structure on said media samples to
form radio frequency identification transponders.
23. The device of claim 21 wherein said value-adding devices
comprise radio frequency identification transponders.
24. The device of claim 23 further comprising means for verifying
that at least some of said radio frequency identification
transponders are operable.
25. The device of claim 24 further comprising means for causing a
failure indicia to be printed on the first surface of each one of
said media samples to which an inoperable radio frequency
identification transponder is attached.
26. The device of claim 21 wherein a value-adding device is
attached to less than all of said plurality of media samples.
27. The device of claim 21 wherein said media samples are selected
from a group consisting of labels, tickets, tags, and cards.
28. A device for use in connection with a thermal transfer printer
that includes a first web that allows a plurality of media samples
to be moved from a supply of media samples as well as a printhead
that prints information on a first surface of said plurality of
media samples, said device comprising: a second web that
temporarily removes the plurality of media samples from said first
web; and an attachment mechanism that attaches a value-adding
device to a second surface of selected ones of said media samples
after information has been printed on the first surface of said
selected ones of said media samples.
29. The device of claim 28 wherein said value-adding devices
comprise radio frequency identification integrated circuits adopted
to make contact with an antenna structure on said media samples to
form radio frequency identification transponders.
30. The device of claim 28 wherein said value-adding devices
comprise radio frequency identification transponders.
31. The device of claim 30 further comprising means for verifying
that at least some of said radio frequency identification
transponders are operable.
32. The device of claim 31 further comprising means for causing a
failure indicia to be printed on the first surface of each one of
said media samples to which an inoperable radio frequency
identification transponder is attached.
33. The device of claim 28 wherein a value-adding device is
attached to less than all of said plurality of media samples.
34. The device of claim 28 wherein said media samples are selected
from a group consisting of labels, tickets, tags, and cards.
35. A method, comprising the steps of: providing a series of media
samples which have a non-existent or predetermined capability of
responding wirelessly to a wireless interrogation signal or
electromagnetic field; and introducing a capability, or modifying
an existing predetermined capability, of only selected ones, but
not all, said series of media samples of responding to a wireless
interrogation signal or electromagnetic field.
36. The method of claim 35 wherein said value-adding devices
comprise radio frequency identification integrated circuits adopted
to make contact with an antenna structure on said media samples to
form radio frequency identification transponders.
37. The method of claim 35 wherein said introducing or modifying
step comprises inserting, applying, forming or otherwise
associating an RFID transponder with only said selected ones of
said series of media samples.
38. The method of claim 37 wherein said RFID transponder is
selected from a group consisting of a chipless transponder, a
passive transponder, and an active transponder.
39. The method of claim 36 wherein said media samples are selected
from a group consisting of labels, tickets, tags, and cards.
40. The method of claim 35 including introducing or modifying an
electrical characteristic of only said selected ones of said series
of media samples.
41. The method of claim 40 wherein said selected ones of said
series of media samples have a preformed characteristic impedance,
and wherein said introducing or modifying step comprises altering
said preformed characteristic impedance.
42. The method of claim 41 wherein said preformed characteristic
impedance becomes a resonant structure by attachment of a
value-adding device to form a passive transponder.
43. The method of claim 41 wherein said preformed characteristic
impedance becomes a resonant structure by attachment of a
value-adding device to form a chipless transponder.
44. The method of claim 41 wherein said preformed characteristic
impedance becomes a resonant structure by attachment of a
value-adding device to form an active transponder.
45. The method of claim 35 wherein said introducing or modifying
step comprises forming or changing a resonant structure on the
selected media.
46. The method of claim 45 wherein said forming or changing step
comprises depositing or altering a pattern of electrically
conductive lines or patterns on the media.
47. A method of configuring on demand a series of labels, tickets,
tags, cards or other media, comprising: moving a series of like or
unlike media; and on demand, selectively applying, inserting, or
otherwise associating with selected ones of said series of like or
unlike media, a discrete, value-adding element.
48. The method of claim 47 wherein said value-adding element
comprises an RFID transponder or other wireless transponder.
49. The method of claim 48 wherein said element is a radio
frequency identification integrated circuit adopted to make contact
with an antenna structure on said media to form a radio frequency
identification transponder.
50. The method of claim 48 further comprising the step of
communicating with said transponder before said associating
step.
51. The method of claim 50 wherein said RFID transponder is
programmed with process control instructions.
52. The method of claim 50 wherein said step of communicating
includes the steps of testing, (i) identifying, or discerning a
characteristic of the transponder, and (ii) reading information
stored in said transponder or writing information into said
transponder.
53. The method of claim 47 further comprising the step of
processing said media before said associating.
54. The method of claim 53 wherein said step of processing includes
printing on said media.
55. The method of claim 54 wherein said step of printing exhibits a
result of said communication with said transponder.
56. The method of claim 55 wherein said printing indicates a defect
or another characteristic or attribute of said transponder.
57. The method of claim 55 wherein said printing exhibits
information read from or stored in said transponder.
58. The method of claim 47 including processing said media after
said associating.
59. The method of claim 58 wherein said processing includes
printing on said media.
60. The method of claim 59 wherein said step of printing comprises
direct thermal printing, laser printing, ink jet printing or
thermal transfer printing.
61. The method of claim 47 wherein said value-adding element has an
adhesive on a surface and is laminated on a carrier, and wherein
said step of associating includes removing said carrier to expose
said adhesive surface.
63. The method of claim 61 wherein said value-adding element is
pressed against said media after said step of removing to cause
adherence therebetween.
63. The method of claim 62 wherein said value-adding element is
tamped against said media pressing.
64. The method of claim 63 wherein said tamping comprises:
providing a fast-acting solenoid; providing a gas spring that is
driven by said solenoid; and utilizing a pressure-applying
mechanism that is coupled to said gas spring and that defines a
surface to press together said media and said element, said gas
spring damping the fast action of said solenoid.
65. The method of claim 47 further comprising the step of placing
said media on a carrier after said value-adding element is
associated, creating a carrier-element-media laminate.
66. The method of claim 65 wherein said carrier is the same carrier
employed to carry said media before said associating step.
67. The method of claim 65 further comprising the step of passing
said carrier-element-media laminate through pinch rollers.
68. The method of claim 65 further comprising the step of affixing
said carrier-element-media laminate to an object, or removing the
carrier and affixing the resulting element-media laminate to an
object.
69. The method of claim 47 wherein said media is moved in a first
direction, and wherein said value-adding element is moved into
position for application in a second direction that is different
from said first direction.
70. The method of claim 69 wherein said second direction is
transverse to said first direction.
71. The method of claim 47 further comprising the step of applying
multiple value-adding elements to a single discrete media.
72. The method of claim 71 wherein at least one of said multiple
value-adding elements is an RFID transponder or other wireless
transponder.
73. The method of claim 72 wherein at least one of said elements is
a radio frequency identification integrated circuit adopted to make
contact with an antenna structure on said media to form a radio
frequency identification transponder.
74. The method of claim 71 wherein each of said multiple
value-adding elements comprises an RFID transponder or other
wireless transponder.
75. The method of claim 71 further comprising the step of
selectively printing said single discrete media.
76. The method of claim 71 wherein said multiple value-adding
elements are applied in sequence.
77. The method of claim 71 wherein said multiple value-adding
elements are applied successively at a single station or at
multiple stations.
78. The method of claim 47 wherein said moving and said otherwise
associating steps are performed under computer program control.
79. The method of claim 47 wherein said media are intermittently
moved, and are stopped during said applying step.
80. The method of claim 47 further comprising the step of moving
said value-adding elements into a position on a dispensing device
which is retracted after a value-adding element is applied to a
media.
81. The method of claim 47 wherein said value-adding element
comprises a promotional device or peel-off label.
82. The method of claim 47 wherein said media includes printed
information on a surface thereof.
83. The method of claim 82 wherein said printed information
indicates whether said value-adding element is defective,
inoperative, or has another characteristic or attribute.
84. The method of claim 82 wherein said printed information
indicates whether the media or element has failed a test.
85. The article of claim 84 wherein said printed information
includes test results or a date or time stamp.
86. The method of claim 47 further comprising the step of printing
said media after the step of associating a value-adding element
with the selected media.
87. The method of claim 47 wherein said step of associating is
performed under computer program control.
88. The method of claim 47 further comprising the step of
associating a plurality of value-adding elements with a single
selected media.
89. The method of claim 47 further comprising the step of
associating value-adding elements with different characteristics or
data with selected different media.
90. The method of claim 47 wherein said media are moved on an
adhesive-backed carrier, and wherein said step of associating
includes delaminating said carrier from a selected media, and
attaching a selected value-adding element to the exposed adhesive
surface of said media.
91. The method of claim 78 wherein said steps of associating
includes supporting a peeled media with vacuum, bringing said
selected value-adding element into position adjacent the supported
media, and pressing the media and element together.
92. The method of claim 91 wherein said selected value-adding
element is tamped into position.
93. The method of claim 91 wherein the selected media and said
selected value-adding element are relaminated after being pressed
together.
94. The method of claim 90 wherein said selected media is
relaminated after said selected value-adding element is
attached.
95. The method of claim 47 wherein said like or unlike media have
different characteristics.
96. The method of claim 47 wherein said associated value-adding
elements have different characteristics.
97. The method of claim 47 wherein, under computer program control
and on demand, individual media having selected characteristics are
custom configured by causing one or more value-adding elements
having chosen characteristics to be associated with said individual
media.
98. The method of claim 97 wherein said individual media is further
customized on demand by processing said individual media under said
computer program control.
99. The method of claim 98 wherein said processing step includes
printing on said individual media.
100. The method of claim 99 wherein said step of printing on said
individual media is related to a value-added element associated
with each one of said individual media.
101. The method of claim 97 wherein said individual media is
further customized on demand by processing of the selected
value-adding element.
102. The method of claim 101 wherein said element is an RFID
transponder, and wherein said processing of said element includes
programming or reprogramming the transponder.
103. The method of claim 47 wherein said selected element is
adhesive backed and carried on a carrier, and wherein said
associating step includes the steps of delaminating a selected
element from its carrier, supporting said delaminated element with
vacuum, bringing said selected element into position adjacent a
media sample, and tamping said media sample and element
together.
104. The method of claim 103 wherein said pressing is performed by
tamping.
105. The method of claim 104 wherein said tamping comprises:
providing a fast-acting solenoid; providing a gas spring that is
driven by said solenoid; and utilizing a pressure-applying
mechanism that is coupled to said gas spring and that defines a
surface to press together said media and said element, said gas
spring damping the fast action of said solenoid.
106. The method of claim 104 wherein the selected media and said
selected value-adding element are laminated after being pressed
together.
107. A method of manufacturing a plurality of adhesive-backed
labels, tickets, tags, cards or other media that is laminated on a
carrier, comprising the steps of: moving a series of media samples;
delaminating at least selected ones of said media samples from said
carrier leaving, in each instance, an exposed adhesive media back
surface; and applying a discrete, value-adding element to said back
surface of the selected media, whereby only the selected ones, but
not all, of said media samples in said series are caused to have
said value-adding element.
108. The method of claim 107 wherein said element is a radio
frequency identification integrated circuit adopted to make contact
with an antenna structure on said media to form a radio frequency
identification transponder.
109. The method of claim 107 wherein said value-adding element is
an RFID transponder or other wireless transponder.
110. The method of claim 109 wherein said RFID transponder is
programmed with process control instructions.
111. The method of claim 110 wherein said instructions control a
process of applying a second value-adding element to the media to
which said value-adding element is applied.
112. The method of claim 109 including the step of communicating
with said transponder before said applying step.
113. The method of claim 112 wherein said communicating includes
testing, identifying, or discerning a characteristic of the
transponder, or reading information stored in the transponder, or
writing information into the transponder.
114. The method of claim 107 including processing said media before
said applying.
115. The method of claim 114 wherein said processing includes
printing on said media.
116. The method of claim 107 wherein said element has a
non-adhesive front surface and an adhesive back surface, and
wherein said front surface of said element is applied to back
surface of said media.
117. The method of claim 116 wherein said element and said media
are pressed together after applying to improve the adherence
thereto.
118. The method of claim 117 wherein said pressing comprises
tamping.
119. The method of claim 107 including placing said media on a
carrier after said element is applied, creating a
carrier-element-media laminate.
120. The method of claim 119 wherein the final carrier is the same
as or different from the initial carrier.
121. The method of claim 119 including passing said
carrier-element-media laminate through pinch rollers.
122. The method of claim 107 wherein an element is applied under
computer program control selectively only to certain of said media
and not to others.
123. The method of claim 107 wherein said carrier is intermittently
fed, and is paused or stopped during said applying step.
124. The method of claim 107 including moving said element into
position for said applying step on a dispensing device which is
retracted after an element is applied to a media.
125. The method of claim 107 wherein said media are fed in a first
direction, and wherein said elements are fed into said position in
a direction transverse to said first direction.
126. An article of manufacture comprising a web, cassette, or other
carrier carrying a series of labels, tickets, tags, cards or other
media, said carrier being characterized by selected ones, but not
all, of said media having associated therewith at least one
value-adding element.
127. An article of claim 126 wherein said element is a radio
frequency identification integrated circuit adopted to make contact
with an antenna structure on said media to form a radio frequency
identification transponder.
128. The article of claim 126 wherein said element comprises an
RFID transponder or other wireless transponder.
129. The article of claim 128 wherein said media having an
associated value-adding element exhibits visible indicia which
indicates whether the transponder is defective, inoperative,
misprogrammed, or has another characteristic or attribute.
130. The article of claim 128 wherein said media having an
associated element exhibits information read from or stored in said
transponder.
131. The article of claim 126 wherein said value-adding element
comprises a second media.
132. The article of claim 131 wherein the second media is a
promotional device.
133. The article of claim 126 wherein said media having an
associated value-adding element exhibits text or other indicia
indicating whether the media or element has failed a test.
134. The article of claim 133 wherein said indicia exhibits test
results or a date or time stamp.
135. The article of claim 126 wherein the carrier carries a
plurality of media having different characteristics.
136. The article of claim 135 wherein the different characteristics
include size, material composition, type, stock, or other
specifications.
137. The article of claim 126 wherein the carrier carries a
plurality of elements having different characteristics.
138. The article of claim 126 wherein the carrier supports selected
media having plural elements.
139. The article of claim 126 wherein the carrier supports selected
media having selectively different preprocessing or
postprocessing.
140. The article of claim 126 wherein the carrier carries selected
media adapted to be applied in groups.
141. An on-demand printer for printing information on a series of
labels, tickets, tags, cards or other media, comprising: a media
feeder; and means for associating a discrete value-adding element
with certain media, but not with other media, in a series of said
media.
142. The printer of claim 141 wherein said element is a radio
frequency identification integrated circuit adopted to make contact
with an antenna structure on said media to form a radio frequency
identification transponder.
143. The printer of claim 141 wherein said value-adding element is
an RFID transponder or other wireless or other wireless
transponder.
144. The printer of claim 143 further comprising means for
communicating with said transponder.
145. The printer of claim 144 wherein said communicating step
comprises (i) testing, identifying, or discerning a characteristic
of the transponder, (ii) reading information stored in the
transponder, or (iii) writing information into the transponder.
146. The printer of claim 141 further comprising means for
processing said media before said value-adding element is
associated with said selected media.
147. The printer of claim 146 wherein said means for processing
includes a printing apparatus.
148. The printer of claim 147 wherein said value-adding element is
an RFID transponder or other wireless or other wireless
transponder, and wherein said printer or printer accessory includes
means for communicating with said transponder.
149. The printer of claim 148 wherein said printing apparatus is
responsive to said means for communicating and prints a result of
said communicating with said transponder.
150. The printer of claim 148 wherein said printing apparatus is
responsive to said means for communicating and prints an indication
of a defect or another characteristic or attribute of said
transponder.
151. The printer of claim 148 wherein said printing apparatus is
responsive to said means for communicating and prints information
based on data read from or stored in said transponder.
152. The printer of claim 142 wherein said means for associating is
controlled by a computer program.
153. Apparatus for associating a selected element with a selected
label, ticket, tag, card or other media, at least one of which
element and media is adhesive-backed and carried on a carrier,
comprising: means for delaminating said one element or media from
its carrier; means for supporting said delaminated element or
media; means for bringing said supported element or media into a
position contiguous with the other of said element or media; and
means for pressing said element and media together to cause
adherence.
154. The apparatus of 153 wherein said means for pressing comprises
a tamper.
155. The apparatus of claim 154 wherein said tamper comprises: a
fast-acting solenoid; a gas spring that is driven by said solenoid;
and a pressure-applying mechanism that is coupled to said gas
spring and that defines a surface to press together said media and
said element, said gas spring damping the fast action of said
solenoid.
156. The apparatus of 136 wherein said means for supporting
utilizes a vacuum, wherein said tamper is reciprocable, and wherein
said tamper includes a bellows through which the vacuum is
delivered to said supported element or media.
157. The apparatus of 136 wherein said supported media is adhesive
backed, and wherein said apparatus includes means for relaminating
said supported media.
158. The apparatus of 153 wherein said value-adding element is an
RFID transponder, and wherein said apparatus includes means for
programming or reprogramming the transponder.
159. The apparatus of 153 wherein said means for bringing includes
means for reciprocating said selected element into said contiguity
and then withdrawing to leave the element.
160. For use in adhering a label, ticket, tag, card or other media
to a value-adding element, one of which media and element have an
exposed adhesive surface, a reciprocable tamping applicator
mechanism comprising: a fast-acting solenoid; a gas spring that is
driven by said solenoid; and a pressure-applying mechanism that is
coupled to said gas spring and that defines a surface that presses
together the media and the element, said gas spring damping the
fast action of said solenoid.
161. The mechanism of claim 160 including a return spring that
returns said pressure-applying mechanism after a stroke by said
solenoid.
162. The mechanism of claim 161 further comprising a plenum
containing said solenoid and said gas spring, as well as a bellows
that is disposed between said plenum and said pressure-applying
mechanism.
163. The mechanism of claim 162 wherein said surface is perforated,
and wherein said mechanism includes means coupled to said plenum
for developing a vacuum in said plenum.
164. A promotional label, ticket, tag, card or other media having
thereon or associated therewith: one or more RFID transponders
programmed with predetermined data representing information about,
or of expected interest to, a particular prospect or class of
prospects for a given product, service, or appeal; and one or more
printings containing information about, or of expected interest to,
said particular prospect or class or prospects, the printed and
programmed information being coordinated and integrated to evoke a
predetermined response from said class of prospects.
165. The media of claim 164 including a plurality of RFID
transponders.
166. The media of claim 165 wherein at least one of said one or
more RFID transponders is programmed with process control
instructions.
167. The media of claim 166 wherein said instructions control a
process of associating a second value-adding element with the media
with which said value-adding element is associated.
168. The media of claim 164 including a peelable or repostionable
RFID transponder.
169. The media of claim 164 including a plurality of separately
applied value-adding elements.
170. The media of claim 164 including a chipless RFID
transponder.
171. The media of claim 170 wherein said RFID transponder is
programmed with process control instructions.
172. The media of claim 171 wherein said instructions control a
process of associating a second value-adding element with the media
with which said value-adding element is associated.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 09/969,114 that was filed on Oct. 1, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention concerns, in a general sense, a method
and apparatus by which, both selectively and on-demand, individual
labels, tickets, tags, cards, and the like (hereinafter
collectively and in individual units referred to as "media", or
individually as "media samples") having selected characteristics
may be custom configured by causing one or more value-adding
elements that have chosen characteristics to be associated with
said media. More particularly, the invention is directed to method
and apparatus for selectively incorporating a value-adding element
such as, for example, a radio frequency identification (hereinafter
called RFID) transponder with individual media samples on a
programmed, on-demand basis.
[0003] Other types of value-adding elements that could be
incorporated into media samples include, for example, shipping
documents; parts to be inventoried, stored or shipped; promotional
devices such as coupons, tokens, currency or other objects having a
value to the recipient; integrated circuits on labels with leads to
be connected to printed antennas; and attached or embedded attached
objects that have associated information on the printed media
relating to their identification or use.
[0004] A thermal transfer printer is typically used to print
individual media samples. Referring to FIG. 1, a side view of a
standard thermal transfer printer mechanism 10 is illustrated. A
label carrier 12 (also generally referred to as a release liner)
carries adhesive-backed, (typically unprinted) diecut labels 14
through the mechanism. Typically, the top surface of each label is
printed with a pattern of ink dots from a thermal transfer ribbon
16 melted onto the label surface as the ribbon and label pass under
a computer-controlled thermal printhead 18.
[0005] An elastomer-coated platen roller 20 typically is driven by
a stepping motor (not shown) to provide both the movement force for
the ribbon and label by means of a friction drive action on the
label carrier 12, as well as acting as the receiver for the
required pressure of the printhead on the ribbon-label sandwich.
This pressure assists in transferring the molten ink dots under
printhead 18 from the thermal transfer ribbon 16 onto the diecut
label 14 surface.
[0006] The thermal transfer ribbon 16 is unwound from a printer
ribbon supply 22, and is guided under the thermal printhead 18 by
idler rollers 24. After the ink is melted from the ribbon 16 onto
the printed diecut label 26, the spent ribbon is wound on a printer
ribbon take-up spindle 28.
[0007] Typically, a media exit 30 is located immediately after the
printhead 18. The now-printed diecut label 26 is often dispensed on
its label carrier 12. If a user desires that the printed diecut
labels be automatically stripped from label carrier, then an
optional peeler bar 32 is utilized. As the label carrier 12 passes
over the sharp radius of peeler bar 32, the adhesive bond is
broken, thereby releasing the printed diecut label 26 from its
label carrier 12. The peeled, printed diecut label 26 is dispensed
at media exit 30. The excess label carrier 12 is both tensioned for
peeling and rewound using optional label carrier take-up mechanism
34.
[0008] As will be described in detail hereinafter, an exemplary
embodiment of the present invention involves selectively and on
demand associating, in the environment of a thermal or thermal
transfer printer, an RFIC transponder with a label, e.g., to create
a "smart" label. Although "chipless" RFID transponders exist and
may be utilized as one example of a value-added element with
certain aspects of this invention, the most common form of an RFID
transponder used in smart labels comprises an antenna and an RFID
integrated circuit. Such RFID transponders include both DC powered
active transponders and batteryless passive transponders, and are
available in a variety of form factors. Commonly used passive inlay
transponders 36 shown in FIG. 2 have a substantially thin, flat
shape. For automatic insertion into labels, the inlay transponders
36 typically are prepared with a pressure-sensitive adhesive
backing, and are delivered individually diecut and mounted with a
uniform spacing on an inlay carrier.
[0009] Inlay transponders have been used as layers of
identification tags and labels to carry encoded data, stored in a
non-volatile memory area data, that may be read wirelessly at a
distance. For example, a camera having a radio-frequency
identification transponder that can be accessed for writing and
reading at a distance is disclosed in U.S. Pat. No. 6,173,119.
[0010] The antenna 38 for an inlay transponder 36 is in the form of
a conductive trace deposited on a non-conductive support 40, and
has the shape of a flat coil or the like. Antenna leads 42 are also
deposited, with non-conductive layers interposed as necessary. The
RFID integrated circuit 44 of the inlay transponder 36 includes a
non-volatile memory, such as an EEPROM (Electrically Erasable
Programmable Read Only Memory); a subsystem for power generation
from the RF field generated by the reader; RF communications
capability; and internal control functions. The RFID integrated
circuit 44 is mounted on the nonconductive support 40 and
operatively connected through the antenna leads 42. The inlays are
typically packaged singulated or on a Z-form or roll inlay carrier
46 as shown in FIG. 2.
[0011] It is known how to utilize on-press equipment for insertion
of transponders into media to form "smart labels," and then to
print information on a surface of the smart labels. See, for
example, an application white paper entitled "RFID Technology &
Smart Labels," dated Sep. 14, 1999, P/N 11315L Rev. 1 of Zebra
Technologies Corporation. See also, for example, a document
entitled "A White Paper On The Development Of AIM Industry
Standards For 13.56 MHz RFID Smart Labels And RFID
Printer/Encoders" by Clive P. Hohberger, PhD, that is dated May 24,
2000. Both of these documents are incorporated by reference into
this application as if fully set forth herein.
[0012] It also is known how to utilize label applicator equipment
to attach pressure-sensitive labels to business forms. Such
equipment has been commercially available on the U.S. market from
several companies for more than one year prior to the filing of
this application.
[0013] Zebra Technologies Corporation is a leading manufacture of a
number of printer related products, including a number of on-demand
thermal transfer printers that incorporate a number of the aspects
of the technology that is disclosed in the two above-referenced
white papers. An example of such a "smart label" printer
commercially available for more than a year prior to the filing of
this application includes Zebra model number R-140.
[0014] Such products are satisfactory for their intended uses.
However, further improvements are desired. Certain features and
advantages of the invention will become apparent from the
description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The objects and advantages of the present invention will
become more readily apparent to those of ordinary skill in the
relevant art after reviewing the following detailed description and
accompanying drawings, wherein:
[0016] FIG. 1 is a side, schematic view of a standard thermal
transfer label printer mechanism;
[0017] FIG. 2 is a schematic view of a plurality of passive
inlay-type RFID transponders as delivered with an adhesive backing
on an inlay carrier;
[0018] FIG. 3 is a side, schematic view of a thermal transfer
printer that incorporates a number of aspects of an exemplary
embodiment of the present invention disclosed in this
application;
[0019] FIG. 4 is a front, sectional view of a portion of the
thermal transfer printer shown in FIG. 3 detailing a tamping
applicator mechanism;
[0020] FIG. 5 is a front, sectional, schematic view of the thermal
transfer printer shown in FIG. 3, wherein a transponder dispensing
mechanism is disposed in a fully retracted initial position;
[0021] FIG. 6 is a schematic, block diagram of some of the key
electronic subsystems and components of the thermal transfer
printer shown in FIG. 3;
[0022] FIG. 7 is a program flow-chart that illustrates certain key
program steps that are executed by the processor unit shown in FIG.
6 for each print job that is performed by the thermal transfer
label printer shown in FIGS. 3-6;
[0023] FIG. 8 is a front, sectional, schematic view of the thermal
transfer printer shown in FIG. 3, wherein the transponder
dispensing mechanism shown in FIG. 5 is disposed in an extended
position so that an RFID transponder is positioned in a desired
position and orientation with respect to a delaminated diecut label
printed by the thermal transfer printer;
[0024] FIG. 9 is a front, sectional, schematic view of the thermal
transfer printer shown in FIG. 5, wherein the tamping applicator
mechanism detailed in FIG. 4 is utilized to permanently affix a
programmed RFID transponder to a media sample that is to be printed
by the thermal transfer printer mechanism and wherein a linear
actuator is used to retract the dispensing mechanism to peel the
inlay carrier from the back of the programmed transponder thereby
exposing its adhesive layer;
[0025] FIG. 10 is a side, sectional, schematic view of the thermal
transfer printer shown in FIG. 3, wherein a diecut label/programmed
transponder sandwich is formed and relaminated to the diecut label
carrier;
[0026] FIG. 11 is a side schematic view of a thermal transfer
printer mechanism, similar to that disclosed in FIG. 3, that
incorporates a number of aspects of a further exemplary embodiment
of the present invention disclosed in this application, and that
allows adhesive-backed value-adding devices such as RFID
transponders to be affixed to stiff media that does not include its
own adhesive layer;
[0027] FIG. 12 is a side schematic view of the thermal transfer
printer shown in FIG. 11, wherein an adhesive-backed, programmed
RFID transponder is disposed in a dispensing position with respect
to the value-adding mechanism;
[0028] FIG. 13 is a side schematic view of the thermal transfer
printer shown in FIG. 11, wherein an adhesive-backed, programmed
RFID transponder is affixed to a stiff media; and
[0029] FIG. 14 is a side schematic view of the thermal transfer
printer shown in FIG. 11, wherein the stiff media, upon which an
adhesive-backed, programmed RFID transponder is affixed, is
advanced to a dispensing position;
[0030] FIG. 15 is a flow-chart that illustrates certain key program
steps that are executed by the processor unit shown in FIG. 6 for
each print job that is performed by the thermal transfer printer
shown in FIGS. 11-14;
[0031] FIGS. 16A though 16D are schematic views of two types of
RFID integrated circuit labels and their attachment to two
corresponding types of printed antennae in order to form actual
RFID transponders in a process using an exemplary variation of the
thermal transfer printer shown in FIGS. 11-15;
[0032] FIGS. 17A and 17B are schematic views of the front and
reverse sides postcard set media that is on-demand printed and to
which various value-added elements are added in a production
process according to an exemplary embodiment of the present
invention;
[0033] FIG. 18 is a representation of the four value-added elements
which are added in certain combinations to the postcard set media
of FIG. 17 by the exemplary production process that is shown in
FIG. 19;
[0034] FIG. 19 is an overhead schematic view of an exemplary
production process incorporating forms of two exemplary embodiments
invention embodiments that is used for selectively and on-demand
configuring the postcard media of FIG. 17 by addition of one or
more value-added elements of FIG. 18;
[0035] FIGS. 20-23 are side, schematic views of a thermal transfer
printer mechanism that incorporates a number of aspects of the
present invention disclosed in this application, and that an RFID
transponder to be selectively and on demand, under program control,
RFID transponder encoded, and attached to an adhesive backed
previously printed diecut label; and
[0036] FIG. 24 is a side, schematic view of a thermal transfer
printer mechanism, similar to FIGS. 20-23, that allows an RFID
transponder to be selectively and on demand, under program control,
RFID transponder encoded, and attached to a linerless media.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0037] While the present invention is susceptible of embodiment in
various forms, there are shown in the drawings a number of
presently preferred embodiments that are discussed in greater
detail hereafter. It should be understood that the present
disclosure is to be considered as an exemplification of the present
invention, and is not intended to limit the invention to the
specific embodiments illustrated. It should be further understood
that the title of this section of this application ("Detailed
Description of Illustrative Embodiments") relates to a requirement
of the United States Patent Office, and should not be found to
limit the subject matter disclosed herein.
[0038] Referring to FIG. 3, a side, schematic view of a thermal
transfer printer 48 that incorporates a number of aspects of the
present invention disclosed in this application is shown. In the
embodiment of the present invention illustrated in FIG. 3, the
thermal transfer printer 48 comprises a standard thermal transfer
printer mechanism that includes all of the components illustrated
in FIG. 1. Printer 48 also includes a value-adding mechanism 50
comprising the identified objects 54-70 that cause a value-adding
device such as, for example, a programmed RFID transponder 52 to be
affixed to a media sample after it is printed as discussed in
greater detail hereinafter.
[0039] It should be understood that value-adding mechanism 50 can
be manufactured and sold apart from the thermal transfer printing
mechanism 10 to allow existing thermal transfer printers to be
retrofitted and, therefore, operate in accordance with a number of
aspects of the invention disclosed in this application. It also
should be understood that, while the illustrated embodiments of the
present invention are disclosed in connection with thermal transfer
printing, the present invention is applicable to other printing
technologies.
[0040] Referring back to FIG. 3, the thermal transfer printer 48
allows an adhesive-backed, preprogrammed RFID transponder 52 to be
selectively bonded to a printed diecut media sample (such as, for
example, a printed diecut label 26) by the value-adding mechanism
50 under program control as discussed in greater detail
hereinafter. The finished printed diecut label/programmed
transponder sandwich (26/52) is presented at media exit 30 with the
label carrier 12 optionally stripped.
[0041] Immediately after printing, the printed diecut label 26 is
released from its label carrier 12 by passing over the sharp radius
of the peeler bar 32. The delaminating process performed by peeler
bar 32 exposes the adhesive on the bottom (unprinted) surface of
the printed diecut label 26.
[0042] The printed diecut label 26 then continues in a straight
line as it passes over a smooth, perforated vacuum guide plate 54
of a tamping applicator mechanism 56. A centrifugal fan 58 extracts
air 60 to create a slight vacuum in the plenum 62. This causes a
slight upward force to be maintained on the printed diecut label 26
that keeps it disposed against the smooth perforated vacuum guide
plate 54. The magnitude of the vacuum force is at such a level that
does not impede the forward motion of the printed diecut label 26.
Plenum 60 is extensible along a central axis that is generally
perpendicular to the path of movement of the label.
[0043] The delaminated label carrier 12 passes around a buffer loop
roller 64 used to control the flow of the label carrier 12 around a
transponder dispensing mechanism 66 (FIG. 6). The buffer loop
roller 64 is free to float up and down, taking up and returning
excess label carrier 12 at different times in the process.
[0044] In an exemplary embodiment, one function of the dispensing
mechanism 66 is to position an adhesive-backed RFID transponder 52
underneath and in operative relation to the printed diecut label
26. RFID transponder 52 is transported on the inlay carrier 46 as
shown. The tamping applicator mechanism 56 (FIG. 3) then extends
the plenum 60 downwardly through the use of flexible bellows 70 so
that the rigid, perforated vacuum guide plate 54 lightly tamps the
printed side of printed diecut label 26. This causes the exposed
adhesive surface of the printed diecut label 26 to be adhered to
the top surface of the RFID transponder 52.
[0045] The label-transponder sandwich (26/52) is now advanced
forwardly, and is passed through a nip 72 that is formed by upper
nip roller 74 and lower nip roller 76. The nip compression both
bonds the adhesive of the printed diecut label 26 to the RFID
transponder 52, and relaminates label-transponder sandwich (26/52)
to the label carrier 12. The formed diecut label-transponder-label
carrier sandwich (26/52/12) then exits the value-adding mechanism
50. As is well known, the label carrier 12 may be optionally
stripped from the diecut label/transponder sandwich (26/52) by the
use of an exit peeler bar 78 and optional label carrier take-up
mechanism 34.
[0046] Typically, only the lower nip roller 72 is driven, this
roller being driven at the same surface speed as the platen roller
20. This allows, for example, printed diecut labels 26 that are
longer than the gap between platen roller 20 and nip 72 to be
accommodated in printer 48 without deforming the printed diecut
label 26.
[0047] FIG. 4 is a detailed sectional view of a portion of the
tamping applicator mechanism 56 shown in FIG. 3. A sealed case 80
and sealed flexible bellows 70 form a closed plenum 62 that
contains a partial vacuum to be applied to the printed media as it
passes through the thermal transfer printer 48. The atmospheric
pressure on the underside of the printed diecut label 26 thus
causes the label to be temporarily adhered to the perforated vacuum
guide plate 54.
[0048] The vacuum in plenum 62 is generated by a centrifugal fan 58
expelling air 60 sucked in through the holes 82 in the perforated
vacuum guide plate 54, passing through internal vents 84 and 86
into blower inlet 88. The flexible bellows 70, attached both via a
drive bracket 104 to the perforated vacuum guide plate 54 and a
baseplate 90, allows the perforated vacuum guide plate 54 to move
up and down while maintaining a sealed vacuum in plenum 62.
[0049] Baseplate 90 forms a part of the housing of the thermal
transfer printer 48 and on which is mounted case 80. The tamping
applicator mechanism 56 is mounted on a case bracket 92, and
includes a two-part solenoid with fixed solenoid coil 94 attached
to a case bracket 92, and solenoid plunger 68 that is attached to
the gas spring plunger 97 via coupler 100. The body of gas spring
98 slides freely within a linear bearing 102 that is affixed to the
perforated vacuum guideplate 54 indirectly through drive bracket
104 as shown. A return spring 106 between the movable coupler 100
and the fixed baseplate 90 provides a force to return the solenoid
plunger 68 and iron disc 96 to their rest position when the
solenoid coil 94 is deenergized.
[0050] One function of the gas spring 98 is to transfer a constant
force to the vacuum guide plate 54 independently of the degree of
plenum extension. The gas spring 98, acting together with return
spring 106 and the driven mass, also provides viscous damping of
the motion of the perforated vacuum guide plate 54, decoupling it
from the snap action of the solenoid plunger 68 when the solenoid
coil 94 is energized, pulling down iron disc 96. A gas damper or
other viscous damper may alternatively be used in place of gas
spring 98 to perform the same function.
[0051] Alternative design concepts are available for the tamping
applicator mechanism if a compressed air source is available. The
partial vacuum in plenum 62 may be generated by passing compressed
air through a venturi. The tamping actuator may be an air cylinder,
with a controlled airflow in said air cylinder replacing the
function of the gas spring 98 in extending downward the perforated
vacuum guide plate 54. Alternatively, tamping may be performed
through use of an air blast through the perforated vacuum guide
plate 54 onto the label in an alternate tamping applicator
mechanism 56 with an non-extensible plenum 62.
[0052] Referring to FIG. 5, a sectional, schematic view of the
thermal transfer printer 48 shown in FIG. 3 is illustrated, wherein
dispensing mechanism 66 is disposed in a fully retracted initial
position. In the embodiment of the invention shown in FIG. 5,
printer 48 includes utilizes an RF signal 108 that is emitted by
transponder programmer antenna 110 to program the memory in RFID
integrated circuit 44. In the fully retracted position shown in
FIG. 5, the now-programmed RFID transponder 52 is positioned
directly under the transponder programmer antenna 110.
[0053] The dispensing mechanism 66 comprises, in the illustrated
embodiment of the present invention, among other things,
transponder carrier rollers 112,113,115 a rigid guide plate 114,
and a linear actuator 116. Linear actuator 116 extends and retracts
the rigid guide plate 114 so that the now-programmed RFID
transponder 52 is placed under the diecut label 26 in the desired
insertion position.
[0054] To position the programmed transponder 52 properly under
printed diecut label 26, a rolamite drive mechanism 118, that is
turned by rolamite stepping motor 120, is synchronized with the
motion of linear actuator 116 to adjust the movement of transponder
inlay carrier 46. This motion is also synchronized with the motion
of a transponder supply roll spindle 122 and an inlay carrier
take-up spindle 124 of inlay carrier take-up spool 132. The supply
roll drive 126 supplies both a computer-controlled unwind
resistance and a braking function on transponder supply roll 128.
The take-up roll drive 130, acting on the inlay carrier take-up
spindle 124, maintains appropriate tension on inlay carrier 46 to
prevent web slippage in the rolamite drive mechanism 118 that
provides peeling tension for stripping the inlay carrier 46 from
the programmed RFID transponder 52 at inlay carrier peeler bar
134.
[0055] A transponder position sensor 136 detects when a transponder
52 is appropriately placed under the transponder programmer antenna
110. The transponder position sensor 136 is part of the control
electronics shown in FIG. 6, and is used to control the motion of
the inlay carrier 46.
[0056] FIG. 6 is a schematic, block diagram of principal electronic
components of the thermal transfer printer 48 that is shown in FIG.
3. In the illustrated embodiment of the invention, printer 48
includes a processor unit 138 with devices attached to a processor
bus 140. The processor unit 138 executes a set of program
instructions that are received from a user via printer I/O port 142
and that are stored in memory 144. As shown in FIG. 6, processor
unit 138 is operatively electrically coupled through processor bus
140 to, among other things, platen roller drive 146 which drives
platen roller 20; thermal printhead 18; transponder programmer 148
which is in turn connected to transponder programmer antenna 110;
transponder position sensor 136; linear actuator 116; supply roll
drive 126; rolamite stepping motor 120 which operate rolamite drive
mechanism 118; inlay carrier take-up roll drive 130; and tamping
solenoid 94.
[0057] FIG. 7 is a flow-chart that illustrates program steps that
are executed by the processor unit 138 shown in FIG. 6 for each
print job performed by the thermal transfer printer 48. Programming
languages that are suitable for use in programming print jobs in
connection with the present invention disclosed in this application
include, for example, ZPL II.RTM. that is the universal language
for printers that are manufactured by Zebra Technologies
Corporation.
[0058] Processor 138 (FIG. 6) first retrieves the parameters of a
print job that a user desires to have done on an on-demand or
selective basis from memory 144 in process 150. For example, a user
may store a set of instructions in the memory 144 that will cause
printer 48 to print a batch of 100 diecut labels, wherein every
other diecut label is to be a "smart label" provided with a
programmed RFID transponder 52. It should be understood that all
"on-demand" printing jobs are intended to be covered in connection
with the present invention to the extent that such printing jobs
include (in the presently discussed preferred execution of the
invention) at least one smart label.
[0059] Referring back to FIG. 7, in program step 152, processor
unit 138 (FIG. 6) determines whether or not a diecut label 14 that
is to be printed is to have a programmed RFID transponder 52
attached to it. If not, then the printed diecut label 26 is formed
in process 154. If the entire print job is determined to be
completed in program step 156, then the program sequence is ended.
If the print job is not done, then in process 158 both a new diecut
label 14 is properly positioned under printhead 18 for the next
printing cycle, and the label format is indexed. Then the processor
unit 138 executes instructions to loop to program step 152.
[0060] If processor unit 138 determines in program step 152 that an
RFID transponder is to be attached to a diecut label 14 that is to
be printed, then an RFID transponder 52 is programmed in process
160, and then is verified as being operable and correctly
programmed in process 162. If the programmed RFID transponder 52 is
correctly verified, then the diecut label 14 is printed in process
163 to form printed diecut label 26, and then the programmed RFID
transponder 52 is attached to the printed diecut label 26 in
process 164 by operation of the value-adding mechanism 50. The
processor unit 138 then executes program step 156 to see if the
print job is performed as above. If the print job is not performed,
then the media and label format are indexed in process 158, and the
processor unit 138 then loops to program step 152.
[0061] Transponder programming and verification typically occurs
prior to printing the media, so that a smart media with a defective
transponder 52 can be identified by printing "void" on it, for
example, rather than the normal label format as, for example,
discussed above. The printer 48 then typically ejects the defective
smart label, and automatically repeats the process until a fully
functional smart label with a properly encoded transponder and the
correct label format is produced. This ensures that the integrity
of the batch of labels that a user desires to manufacture in
connection with a particular on-demand print job is accurately
made. To wit, if in verification process 162 the processor unit 138
determines that the programmed RFID transponder 52 is not operable,
then it may be disposed of directly. Alternatively, a suitable
indicia such as, for example, "VOID" is printed in process 163 on
the diecut label 26, and the inoperable RFID transponder 52 is
attached to the "VOID" printed label in process 164 in order to
expel the properly-identified defective transponder 52 from the
printer 48. The processor unit 138 loops in processes 160 and 162,
etc., to program and verify a new RFID transponder 52, printing an
appropriate diecut label 26 and attaching them together in process
164 continues until a correctly printed diecut label 26 with an
embedded, verified, programmed RFID transponder 52 is completed.
Then the program continues by testing if the print job is complete
in program step 156.
[0062] FIGS. 8-10 illustrate one example of a process for attaching
a programmed RFID transponder 52, or any other suitable
value-adding element, to printed diecut label 26 (step 164 in FIG.
7). The processor unit 138 (FIG. 6) causes the linear actuator 116
to extend and causes the supply roll drive 126 to unwind the
transponder supply spool 128, while rolamite stepping motor 120 and
take-up roll drive 130 also unwind an approximately equal amount of
inlay carrier 46. This continues until a new, unprogrammed RFID
transponder 166 is positioned properly within transponder position
sensor 136.
[0063] In FIG. 9, the processor unit 138 (FIG. 6) now activates the
tamping applicator mechanism 56. By applying an electric current to
solenoid coil 94, the magnetic force on iron disc 96 actuates
solenoid plunger 68, which, acting through coupler 104, and gas
spring plunger 97, thus compresses gas spring 98. A nearly constant
tamping force independent of extension is transmitted by the body
of gas spring 98 onto drive bracket 104 that extends the flexible
bellows 70 and thus plenum 62. This causes the rigid perforated
vacuum guide plate 54 to press the adhesive side of printed diecut
label 26 against the programmed transponder 52, using the rigid
guide plate 114 as an anvil. This adheres the programmed RFID
transponder 52 to the printed diecut label 26.
[0064] Once tamping takes place as, for example, described above,
the processing unit 138 now causes the linear actuator 116 to
retract, while keeping the supply roll drive 126 braked so that the
new unprogrammed RFID transponder 166 remains fixed under
transponder position sensor 136. The processor unit 138 activates
rolamite stepping motor 120 in coordination with the motion of the
linear actuator 116, so that rolamite stepping motor 120 acts
through rolamite drive mechanism 118 to takes up and maintains
tension on the excess inlay carrier 46. Tension on the rolamite
drive mechanism is maintained by energizing the take-up roll drive
130, which also causes the excess inlay carrier 46 to wind onto the
take-up roll spindle 124.
[0065] The retracting motion of the linear actuator 116 on the
guide plate 114 together with the tension on inlay carrier 46, aids
in peeling the inlay carrier 46 at the inlay carrier peeler bar 134
from the adhesive layer on the bottom of programmed RFID
transponder 52, which is now adhered to the printed diecut label
26. This peeling process continues until the guide plate 114 plate
is completely retracted to the position shown in FIG. 5. The new,
unprogrammed RFID transponder 166 is now properly positioned under
transponder programmed antenna 110 for immediate programming.
[0066] Now that the programmed RFID transponder 52 has been bonded
to the printed diecut label 26, the processor unit 138 deactivates
tamping applicator mechanism 56, which retracts under the force of
return spring 106.
[0067] In FIG. 10, the diecut label/transponder smart label
sandwich (26/52) is advanced by the platen roller 20, slides across
the smooth perforated vacuum plate 54 until the next, unprinted
diecut label 14 is positioned under printhead 18 for the next
printing cycle. Driving of the sandwich (26/52) continues by the
driven nip roller 76, and relamination with the label carrier 12
occurs in nip 72. The production of the printed and programmed RFID
smart labels with embedded programmed RFID transponder 52 is now
finished, and the laminated smart label (26/52/12) is delivered at
label exit 30. As shown, label carrier 12 may also be optionally
peeled away from the printed smart label (26/52) in a manner
similar to that described in FIG. 1.
[0068] Alternatively, the label carrier 12 delaminated at 32 (FIG.
3) may be removed from the system by, for example, utilization of a
take-up mechanism that is similar to 34. In this example, a second
supply roll of label carrier 12 may be used for relamination of the
label sandwich (26/25/12) at nip 72, and the buffer loop roller 64
eliminated.
[0069] FIGS. 11-15 illustrate an exemplary modification of the
thermal transfer printer 48 (as shown FIG. 3) that is designed for
use with tickets, tags, plastics cards, and other stiff media that
does not contain an adhesive layer. This ticket and tag printer 168
comprises thermal transfer printing mechanism 10; tamping
applicator mechanism 56; dispensing mechanism 66 and cutter
mechanism 170. The embodiment shown in FIGS. 11-15 also is useful
for applying a self-adhesive transponder to a surface of a printed
self-adhesive label
[0070] Note that the items that are illustrated in the FIG. 3-10
embodiment but are not specifically shown in FIGS. 11-13 may be
present in an actual product that incorporates all or some of the
inventions disclosed in the totality of FIGS. 3-14. However, since
said unshown components do not have a role in the further exemplary
embodiment illustrated in FIGS. 11-14, they are, therefore, are not
shown in FIGS. 11-14 for purposes of simplicity.
[0071] Referring to FIG. 11, the programmed RFID transponder 52 is
itself formed as a transponder label 172 by adhering a diecut
transponder facestock 174 to the top surface of the
adhesive-backed, programmed RFID transponder 52 on inlay carrier
46. As stiff media 176 often is supplied in continuous form, it may
be optionally cut to length after printing. An optional cutter 170,
including cutter blades 178, is shown in FIG. 11 between the nip
rollers 74, 76 and media exit 30. The electrically-operated cutter
mechanism 170 is additionally connected through the processor bus
140 (FIG. 6) to processor unit 138 (FIG. 6) as part of thermal
transfer ticket and tag printer 138.
[0072] In FIG. 12, the tamping applicator mechanism 56 is extended
in a manner similar to the description for FIG. 9. The processing
unit 138 (FIG. 6) energizes the solenoid coil 94 of the tamping
applicator mechanism 56, which extends the flexible bellows 70 and
presses the perforated vacuum guide plate 54 against the
transponder label 172. In a manner similar to FIG. 9, a guide plate
(not shown) of the dispensing mechanism 66 then is retracted,
peeling the inlay carrier 46 away from the transponder label 172 at
inlay carrier peeler bar 134 (see FIG. 9), thereby leaving the
lower adhesive surface of transponder label 172 exposed.
[0073] In FIG. 13, when solenoid coil 94 is deenergized, the
tamping applicator mechanism 56 is then fully retracted by spring
106, with transponder label 172 remaining held against the
perforated vacuum guide plate 54 by the vacuum force generated by
centrifugal fan 58. The exposed lower adhesive surface of the
transponder label 172 is now positioned above the path of stiff
media 176.
[0074] The stiff media 176 (which can be a ticket, tag, plastic
card, laminated label stock, or the like) is now printed and
dispensed forward by platen roller 20 to the point where the
transponder label 170 is to be placed on it. See FIG. 14. When the
printed stiff media 176 is in the correct position, tamping
applicator mechanism 56 presses the transponder label 172 onto the
printed stiff media 176. Note that the during the tamping process,
the guide plate of dispensing mechanism 66 may be optionally
extended under the printed stiff media 176 so that rigid guide
plate 114 acts as an anvil for the tamping applicator mechanism
56.
[0075] In FIG. 14, the transponder label/printed stiff media
sandwich (172/176) now continues forward through the nip rollers 74
and 76, where the transponder label 172 is permanently bonded to
the printed stiff media 176 by the compression provided by nip
rollers 74 and 76. Then, if discrete stiff media 176 are used in
forming the transponder/media sandwich (172/176), the sandwich is
ejected through media exit 30.
[0076] In the case of continuous stiff media 176, the stiff media
trailing the transponder media sandwich (172/176) may be optionally
cut to length using the cutter mechanism 170. This is accomplished
under control of the print job software, as shown in FIG. 15, by,
for example, processor unit 138 activating electrically-controlled
cutter blades 178. In that case, the cutoff length of smart ticket
or tag exits at 30, and remaining the stiff media 16 is retracted
by platen roller 20 to its position it under the printhead 18 for
the start of the next printing cycle.
[0077] FIG. 15 is a flow-chart that illustrates program steps that
are executed by the processor unit 138 shown in FIG. 6 for each
print job performed by the thermal transfer printer 48. Note that
many of the program steps and processes in FIG. 15 are the same as
or similar to those in the flow chart of FIG. 7. The processor unit
138 first retrieves the parameters of a print job that a user
desires to have performed on an on-demand basis from memory 144 in
process step 150. For example, a user may store a set of
instructions in the memory 144 (FIG. 6) that will cause ticket and
tag printer 168 to print a batch of 21 tickets from a roll of
continuous stiff media 176, wherein only the first ticket is to be
a "smart ticket" provided with a programmed RFID transponder label
172. It should be understood that all "on-demand" printing jobs are
intended to be covered in connection with the present invention to
the extent that such printing jobs include (in the described
preferred execution of the invention) at least one smart ticket or
tag.
[0078] Referring to FIG. 15, processor unit 138 (FIG. 6) determines
in program step 180 whether or not a stiff media sample that is to
be printed is to have a programmed RFID transponder label 172
attached to it. If not, then the printed ticket is just formed in
process 181. In program step 182, it is determined if the media
sample is to be cut. When discrete media such as plastic cards are
used, then in process 183 the finished media sample is simply
ejected at the media exit 30, and a new media sample is positioned
under the printhead 18 for the next printing cycle.
[0079] When printed continuous stiff media is to be cut, then in
process 184 the continuous stiff media 176 is positioned to the
cut-off point between cutter blades 178 of cutter mechanism 170.
The processor unit 138 the activates the electrically-operated
cutter mechanism 170 to cut off the printed ticket, tag, smart
ticket or smart tag for the stiff media supply and deliver it at
media exit 30. The continuous stiff media is then backfed using the
platen roller 20 to the start of print position under printhead 18
for the next print cycle.
[0080] If the entire print job is determined to be completed in
step 156, then the program sequence is ended. If the print job is
not done, then the media print format is indexed in step 185, and
then the processor unit 138 loops to program step 180.
[0081] If processor unit 138 determines in program step 180 that an
RFID transponder is to be attached to the next ticket or tag that
is to be printed, then an RFID transponder label 172 is programmed
in process 160, and then is verified as being operable and
correctly programmed in process 162. If the programmed RFID
transponder label 172 is correctly verified, then the ticket or tag
is printed in process 181, and then the programmed RFID transponder
label is attached to the printed media sample by operation of the
value-adding mechanism 50 in process 186. The processor unit 138
then executes program step 182 to see if the media is to be cut,
taking the appropriate action as described above; then program step
156 to print job is done, also as described above.
[0082] Transponder programming and verification typically occurs
prior to printing the media, so that a smart media with a defective
transponder label 170 can be identified by printing "void" on it in
step 187 rather than the normal media format 181. The ticket or tag
printer 168 then typically ejects the defective smart ticket or tag
at media exit 30, and automatically repeats processes 160 and 162,
etc., until a fully-functional smart ticket or tag with a properly
encoded transponder and the correct printed media format is
produced, in a manner similar to that as described in FIG. 7.
[0083] Additionally, a variation of the embodiment shown in FIGS.
11-15 may be used to actually form transponders by printing an
conductive antenna on the media sample and then attaching labels
comprised of RFID integrated circuits with electrical contacts to
that antenna (for example the Motorola BiStatix.TM. "interposer";
and those made by Marconi using an Intermec Intellitag.RTM. 900 MHz
or 2.45 GHz RFID integrated circuit).
[0084] For example, in FIG. 16A a BiStatix label 190 based on
Motorola BiStatix.TM. integrated circuit 191 is formed on
transparent nonconductive label stock 192 by first forming two
conductive mounting pads 193 and bonding them to two antenna
contacts on Motorola BiStatix.TM. integrated circuit 191. These
BiStatix labels 190 in roll form are used as transponder supply
roll 128 in ticket and tag printer 168. During the printing
process, by proper choice of thermal transfer ribbon 16 and
nonconductive media 194, two printed conductive carbon antenna
panels 195 can be formed on the ticket or tag. The value-adding
mechanism 50 can be used to attach the conductive mounting pads 193
of each BiStatix label 190 to the two printed conductive carbon
antenna panels 195 to form a complete RFID transponder, as shown in
FIG. 16B. By proper placement of the transponder programmer antenna
110, the electrostatic-coupled RFID transponder so formed then may
be programmed.
[0085] More conventional magnetically- or
electromagnetically-coupled transponders also may be formed this
way. In FIG. 16C, a 2.45 GHz RFID Intellitag label 196 based on an
Intermec Intellitag.RTM. integrated circuit 197 is formed on
transparent nonconductive label stock 192 by with two metal
contacts 198 bonded to the two antenna contacts on an Intermec
Intellitag.RTM. integrated circuit 197. A rolls of these Intellitag
labels 196 is used as transponder supply roll 128 in ticket and tag
printer 168. During the printing process, by proper choice of
thermal transfer ribbon 16 and nonconductive media 194, a 2.45 GHz
conductive silver ink folded dipole antenna 199 can be formed. The
value-adding mechanism 50 can be used to attach the two metal
contacts 198 of the Intellitag label 196 to the ends of the
conductive silver ink folded dipole antenna panels 199 to form a
complete RFID transponder, as shown in FIG. 16D. By proper
placement of the transponder programmer antenna 110, the
electromagnetically-coupled transponder so formed then may be
programmed.
[0086] The present invention provides a number of distinct
advantages, either individually and/or collectively. Such
advantages include, for example, the following.
[0087] 1. The ability to selectively add an RFID transponder to a
conventional on-demand printed media sample under program control,
thereby converting a conventional label into a "smart" RFID
enhanced media sample;
[0088] 2. The ability to selectively create an RFID transponder
using a printed antenna and applied RFID integrated circuit on a
conventional on-demand printed media sample under program control,
thereby converting a conventional label into a "smart" RFID
enhanced media sample;
[0089] 3. The ability to provide a single label, ticket tag or
plastic card printer that can produce, on-demand, either
conventional or "smart" RFID media using the same conventional
label, ticket, tag stock or cards; and
[0090] 4. The elimination of the need for pre-converted RFID smart
media, thereby removing the attendant cost of these items being
specially produced by a label converter and inventoried by the
user.
[0091] Additional advantages of the present invention include the
following.
[0092] 5. The impact of the "lumpy" transponder on print quality in
producing a smart media sample is eliminated because printing of
the media is done before the RFID transponder is embedded in or
adhered onto the final media sample;
[0093] 6. The ability to design an add-on option to a conventional
label, ticket, tag or plastic card printer to enhance it to produce
smart labels, tickets, tags or plastic cards on an as-needed
basis;
[0094] 7. The ability to cause a single printer to produce either
conventional or smart media using conventional media supplies as a
basis (as the smart media can be produced only when needed using
the on-demand basis label format software control);
[0095] 8. The removal of the need for a label converter to provide
special rolls of smart labels for on-demand printers, with the
attendant extra costs of making and inventorying special smart
label stock.
[0096] 9. The removal of the need for the user to have a separate
thermal transfer printer to produce smart labels;
[0097] 10. The elimination of user dependence on smart label
converters, thereby allowing the user to use their existing
converter;
[0098] 11. The allowance of designs that permit all printers in a
product line to do, on an on-demand, programmed-controlled basis,
both conventional labels, tickets, tags and cards, and also smart
labels, tickets, tags and cards; and
[0099] 12. The reduction of the cost overhead and complexity
barriers of adding smart label capability to an existing
conventional labeling process. Still further advantages and
benefits follow.
[0100] As described above in the list of advantages, the invention
makes possible a truly on demand, custom configuration of any
selected one, or all, of the media to have an RFID transponder of a
particular type or capability, programmed with particular data, and
preprinted or post-printed or otherwise processed. This implies
that end users do not have to install a variety of printers or
other systems in order to take care of the requirements of various
customers or applications. Since entire rolls of unprinted smart
labels (each possibly having a different material, adhesive, label
form factor or type of transponder) do not have to be stocked, the
cost savings are significant. The capital and maintenance costs of
single purpose lines or machines is avoided. Since the entire
process is under computer program control, errors which inevitably
result in manual changeover from plain labels to RFID labels, for
example, is eliminated. One machine or system can now handle all
needs.
[0101] In a more general sense, the present invention concerns a
method of configuring on demand a series of labels, tickets, tags,
cards or other media. The method comprises feeding a series of
media which may be alike or different, and, on demand, selectively
applying, inserting, or otherwise associating with certain media
but not with other media in the series one or more discrete,
value-adding elements. In the described preferred embodiment the
elements are RFID transponders, however, as will be described,
other value-adding elements may be associated with the selected
media.
[0102] A third embodiment illustrating the more general nature of
the on-demand configuration process for media is the application
shown in FIGS. 17-19. With the advent of "mass customization"
marketing, and the developments in prospect-specific data resources
available today, it is possible to narrowly target a very specific
group of prospects, about which much is known concerning their
identification, attributes, predilections, purchasing habits and
other personal characteristics. The present invention gives total
flexibility in appealing to particular purchasing interests and
other characteristics of a particular set of prospects or past
customers.
[0103] In this illustrative hypothetical application, Travel Card
Company wishes to send custom configured promotional media to a
selected customer base. Its customers consist of three classes:
Green, Gold and Platinum card members. Green Members are occasional
travelers, mostly for vacations, and comprise the lowest category
of card usage. Gold Members use the card frequently, primarily for
business, but often take vacations abroad, and represent a smaller
population with much higher usage than Green Members, and as a
class represent most of the travel dollars spent with Travel Card
Company. Platinum Members are a much smaller class, with an average
annual card usage five times that of Gold Members, mostly spent on
international travel, using first class airfare and luxury hotels
and restaurants; they often mix business and pleasure travel, and
they often travel with spouses or "significant others." They are
highly desirable customers for the luxury class travel and
merchandise companies.
[0104] The promotional media is here a custom postcard set 200 as
shown in postcard set front 202 and postcard set reverse side 204
in FIGS. 17A and 17B, comprised of customer addressed postcard with
detachable return postcard. The postcard set front side 202 is
intended to be on-demand printed with customer-specific mailing
address 206 and selected promotional travel offerings incorporating
value-adding elements. The reverse side 204 of postcard set 200 is
entirely preprinted with fixed information: The postcard set
reverse side 204 of the customer addressed post card is printed
with pictorial information 208 about luxury cruise A and pictorial
information 210 about luxury cruise B; the postcard set reverse
side 204 of customer return post card is printed with Travel Card
Company return address 212 and business reply postage 214. Post
card set 200 is intended to be machine folded and sealed so that
the customer address 206 and business postage franking 216 is
visible on initial mailing.
[0105] The postcard set front side 202 of is on-demand printed with
customer specific information and promotional offers, including
certain value-adding elements from FIG. 18 that are placed in areas
218 and 220 depending on the promotional offer being made to the
specific customer identified in customer address 206. The postcard
set front side 202 of return postcard has luxury cruise A
description 222 with associated information request area 224; also
luxury cruise B description 226 with associated information request
area 228. In addition, for Gold and Platinum Members, there are
special on-demand printed promotional areas that are not printed
unless special offers are being made; this includes promotional
area 230 with customer-markable response areas 232 and 234,
associated information request area 236, and a reserved area
238.
[0106] In FIG. 18, four value-adding elements 240 through 246 are
shown. Repositionable 2-class cruise upgrade coupon 240 intended to
be offered to Green Members only; repositionable 3-class cruise
upgrade coupon 242 is intended to be offered only to Gold and
Platinum Members; the appropriate coupon is to be placed on
customer address postcard in cruise upgrade offer area 218.
Permanently attached RFID transponder label 244 is to be placed in
Platinum Member promotional reserved area 238 on postcard set
reverse side 204 (see FIG. 17B) of all mailings to Platinum
Members. It carries in the transponder memory the Platinum
Member-specific address, travel history and card usage information
248. It is preprinted with an offer of free global Internet E-mail
service by an Internet Service Provider associated with Travel Card
Company which also advertises on-line only luxury merchandise. When
a Platinum Member accepts the free E-mail offer, the return
postcard is given to the Internet Service Provider and the
information stored in the memory of the RFID transponder label 244
is read wirelessly and used to automatically set up the Platinum
Member's global E-mail account. In case of transponder failure, the
key customer information, namely name and card number, are also
on-demand printed in customer name and card number field 250.
[0107] Repositionable free flight coupon 246 contains an offer from
Urban Legends Helicopter Service for a free helicopter flight form
the main airport to a downtown heliport in New York City, Chicago,
Paris or Tokyo. It is intended to be offered only to those Gold and
Platinum Members which also stay more than a total of fifteen
nights each year in the luxury downtown hotels in any or all of
those four cities. When appropriate for use with a given card
member, it is placed in special offer area 220 on customer address
postcard.
[0108] In accordance with certain aspects of the production process
to be described in detail below, an on-demand printed postcard set
is produced for each Green, Gold or Platinum Member with selected
value-adding elements from FIG. 18 to be placed as described above
depending on the member's card color and travel history. When
received by each member, if so interested, the member takes
specific actions with respect to the repositioning any value-added
coupons present and marking the customer response areas 232 and 234
(if present) to accept or reject the associated promotional offers.
The interested member then mails the postage-paid return card to
Travel Services Company to implement the requested promotional
offers.
[0109] Returning to FIG. 17, if the member is interested in
receiving the information about luxury cruise A, then the offered
value-adding coupon (either 240 or 242) in cruise upgrade offer
area 218 is removed and placed in information request area 224.
Similarly, information about luxury cruise B may be requested by
removing said repositionable cruise upgrade coupon from offer area
218 and placing it in information request area 228. Should a
Platinum Member decide to accepted the free global E-mail service
offered by the preprint on RFID transponder label 244, he checks
the "Yes" box in custom-printed response area 232 (printed only
when RFID transponder label 244 is also attached in reserved are
238). Should the selected Gold and Platinum Members receiving the
special free flight offer coupon 248 from Urban Legend Helicopters
decide to accept it, said member removes the coupon from special
area 220 and places it in special area 238, and checks the box in
custom printed area 236 for the city in which the member would like
the free flight.
[0110] FIG. 19 is a top schematic view of one example of a
three-stage production process embodying exemplary aspects of the
invention in three different forms that may be used to prepare the
finished postcard sets. A supply of postcard stock 300 which is
preprinted on the reverse side of each postcard set 200 with fields
208, 210, 212, 214 and 214 (see FIG. 17), and possibly preprinted
only on the front side with business postage franking 216 (all
though forms of this may also be on-demand printed). Postcard stock
300 passes through postcard printer 302, which contains a variation
of the second invention embodiment 168 using externally
preprogrammed transponder labels. This postcard printer 302 is
driven through connection 304 to factory controller 306, which in
turn is connected through local area network 308 to main computer
310 which includes processing program 312 and card member database
314. Certain file information from each entry in card member
database 314 is selected by processing program 312 and is
transferred over local area network 308 to factory controller 306
for use by factory control program 316 to direct the production
operations in the preparation of each corresponding postcard set
200.
[0111] Typically, the member files in card member data base 314 are
in sequential order with respect to card number, but random by
membership color as this may change during the life of a card
member account. For each Platinum Member file encountered,
transponder label printer 318, which contains the first invention
embodiment described above, is directed by factory controller 306
over connection 320 to prepare an RFID transponder label 244. Using
diecut label supply 322 and self-adhesive RFID transponder supply
324, the transponder label printer 318 produces a sequential
transponder label strip 326 of programmed RFID transponder labels
244, each of which has been preprinted with the Platinum Member's
name and card number, and embeds an RFID transponder encoded with
relevant card member information from database 314. This sequential
transponder label strip 326 of RFID transponder labels 244 is used
as the RFID transponder label supply for postcard printer 302.
[0112] The Stage 1 production operation is performed by postcard
printer 302, and includes all the on-demand printing operations. As
postcard printer 302 is directed to initiate preparation of a
postcard set 200 for each card member, the required card member
information is transferred to it over connection 304. If
information for a Green or Gold Member is found, then just the
appropriate on-demand printed customer mailing address 206 on the
front side of card, and luxury A and B cruise information 222 and
226, respectively, are printed on the postcard set front side 202
of return mail card (see FIG. 17). If a Gold or Platinum Member is
found to qualify for the free flight coupon, then offer
customer-markable response area 232 is also printed. For all
Platinum Members fields 206, 222, and 226 are printed the same as
for a Gold Member, and the customer-markable response area 234 to
special lifetime E-mail offer is also printed. It is first verified
that the corresponding RFID transponder label 244 is in position
for placement; then said RFID transponder label 244 is placed in
reserved field 238. A schematic example of first Green Member
postcard set 328 and first Platinum Member postcard set 330 as
outputs of Stage 1 production are shown in FIG. 19.
[0113] In Stage 2 of the production process, additional
value-adding processes incorporating the invention are used to
complete the custom configuration of the postcard set media by the
addition of one or more of selected value-added elements shown in
FIG. 18. First additional value-adding process 332 selectively adds
2-class cruise upgrade coupon 240 from first coupon supply 334 to
postcard set 200 when so directed by production controller 306 over
connection 336. Second additional value-adding process 338
selectively adds 3-class cruise upgrade coupon 242 from second
coupon supply 340 to postcard set 200 when so directed by
production controller 306 over connection 342. Third additional
value-adding process 344 selectively adds free flight coupon 246
from third coupon supply 346 to postcard set 200 when so directed
by production controller 306 over connection 348.
[0114] Exemplary output from the Stage 2 are shown as custom
configured postcard media 350, 352, 354 and 356. Second Platinum
Member postcard set 350 was custom configured with free flight
coupon 246 using third additional value-adding process 344; 3-class
cruise upgrade coupon 242 added by second additional value-adding
process 338; and RFID transponder label 244 as configured by the
first invention embodiment in transponder label printer 320 and
placed by second invention embodiment in postcard printer 302.
First Gold Member postcard set 352 was custom configured with only
3-class cruise upgrade coupon 242 added in second additional
value-adding process 338. Second Green Member postcard set 354 was
configured for a Green Member receiving only 3-class cruise upgrade
coupon 240 added in first additional value-adding process 332.
Second Gold member postcard set 356 is custom configured with
cruise upgrade coupon 242 from second additional value-added
process 338 and free flight coupon 246 from third additional
value-adding process 344.
[0115] In Stage 3 of the production process of FIG. 19,
sheeter-folder-sealer process 358 is used to prepare the custom
configured postcard media for mailing, under control of production
controller 306 using connection 360. The continuous postcard media
is cut part into individual postcard sets 200, folded and sealed to
expose the front of the customer address postcard set front side
202. An example of Stage 3 output, namely a finished postcard set
362 is shown being ejected from sheeter-folder-sealer 358 on to the
stack of completed custom-configured postcard media 364.
[0116] A number of alternatives of the FIGS. 17-19 method and
system are contemplated by the present invention. For example, in
one variant coupons 240, 242, and/or 246 also have RFID
transponders. The transponders in these value-adding elements may
be programmed with the same data as described above with respect to
transponder 244. What is unique in this variant is that the element
which is peeled off and transferred to another part of the media
(which could also be to another separate media) is or has embodied
therein a memory containing useful information which can be
accessed wirelessly by the organizer of the promotion or another
involved party.
[0117] Alternatively, rather than an RFID transponder of the type
having a memory, a chipless RFID transponder may be substituted.
For example, rather than a transponder such as shown at 244, in
space 238 on card set 200 a resonant series of conductive lines may
be printed on the card. Or a variety of other chipless RFID
technologies may be employed. Integrated circuit labels, of a type
similar to those shown in FIG. 16, may also be used with printed
antennae to form RFID transponders in situ.
[0118] In accordance with exemplary aspects of the present
invention, as described in FIGS. 17-19, on demand a mailer is being
sent which has the following attributes:
[0119] 1) various personalized on demand printings on the media
directed to appeal to known interests of the target prospect;
[0120] 2) various targeted coupons or other value-adding elements
placed on demand on the media;
[0121] 3) RFID transponders containing target specific data which
will be used in after processing the card when returned;
[0122] 4) on demand printing on the transponders which is tied to
the target and the stored information;
[0123] 5) plural value-adding elements which not only relate to the
target prospect, but to each other as well, to form a coordinated,
prospect-specific appeal;
[0124] 6) an action response item (the transferred coupons)
prompting the prospect to take action which is not just a generic
"YES I WANT TO BUY" token, but a response item which is
personalized for the particular prospect.
[0125] In short, the card may have as many as half dozen or more on
demand printings or value-adding elements which are coordinated to
develop a powerful personalized and integrated sales appeal.
[0126] In yet another execution of certain exemplary aspects of the
principles of the invention, a transponder 52 may be programmed
with instructions which control subsequent processes such as the
application of another value-adding element on the same media. For
example, in a variant of the FIGS. 17-19 embodiment wherein the
value-adding processes 332, 338 and/or 344 are distributed and not
under the control of controller 306, RFID transponder label 244
could be programmed with instructions which would be read as part
of the value-adding processes to determine the type, content, or
other characteristic of a value-adding element to be added to the
media containing the transponder label 244. Alternatively, for
example, address data stored in the label 244 could be read at a
postage metering station to determine the correct postage.
[0127] Thus, the embodiment of FIGS. 17-19 illustrates certain
exemplary features of the present invention as a method of
configuring on demand a series of labels, tickets, tags, plastic
cards, postcards or other media by selectively applying, inserting,
or otherwise associating with certain media--but not with other
media--in the series one or more discrete, value-adding elements.
And, preferably, in a coordinated integration therewith, the
application of one or more printings on the media and/or the
value-adding elements to provide further flexibility in the
presentation of information to end users and other.
[0128] Referring to FIG. 20, one embodiment of a transponder
applicator mechanism 300 is illustrated that selectively and on
demand, under program control, encodes an RFID transponder, and
attaches the same to an adhesive backed previously printed diecut
label 26. The transponder applicator mechanism 300 may be
integrated with existing thermal transfer printing mechanism 10, or
it may be attached to a thermal printer as an optional
accessory.
[0129] In the embodiment of the invention illustrated in FIG. 20,
the printed diecut label 26 is removed from its label carrier 12 by
the action of peeler bar 32 and label carrier take-up mechanism 34.
During its forward motion that is driven by platen roller 20, the
printed surface of the printed diecut label 26 maintains a
substantially straight path towards media exit 30 along a
perforated vacuum guide plate 302. The light vacuum force 304, that
is generated by a centrifugal blower 306 that expels air 308 from a
closed plenum 310, controls the path of, but does not impede the
motion of, diecut label 26.
[0130] When formation and encoding of a smart label is desired,
then, prior to printing the diecut label 26, an RFID transponder
312 is in a position under antenna 314. Antenna 314 encodes the
RFID transponder 312, and verifies the same using radio signal 316
in the manner described in this application. In the illustrated
embodiment, the transponders are adhesive backed, and are supplied
diecut from an inlay carrier 318 by inlay supply mechanism 320.
[0131] Referring to FIG. 21, when the leading edge of the next
diecut label 14 is in position under the printhead 18, the motion
of the platen roller 20 and label carrier take-up mechanism 34
stops. Also, forward motion of the printed diecut label 26
continues now to be driven by the siliconized drive roller 322,
which is typically operationally coupled to the drive of platen
roller 20, but runs at a slightly faster surface speed. It presses
lightly against the adhesive side of printed diecut label 26 and
against spring loaded nip roller 324.
[0132] Assuming that correct encoding and verification has taken
place, when the printed diecut label 26 is at the correct position
in its forward travel, the encoded RFID transponder 312 is now
moved in forward by the action of inlay carrier take-up mechanism
326 on inlay carrier 318. As the transponder 312 reaches the top of
its path over roller 328, the linear actuator 330 now advances
small roller 328, which presses the leading edge of encoded
transponder 312 against the adhesive side of printed diecut 26.
[0133] Both the inlay carrier 318 and the printed diecut label 26
are now driven forward at the same surface speed, so that the
encoded RFID transponder 312 is peeled from the inlay carrier 318
as it passes over the small roller 328, as shown in FIG. 22. Once
the a encoded RFID transponder 312 is completely peeled from the
inlay carrier 318, then the linear actuator 330 retracts, and the
next unencoded transponder 332 in now in position under antenna 314
for use in the next smart label dispensing cycle.
[0134] Referring to FIG. 23, forward motion continues until the
peeled printed diecut label and encoded RFID transponder sandwich
(26/312) in delivered at media exit 30. The pressure of the nip
formed by siliconized drive roller 322 acting on the sandwich
against spring loaded nip roller 324 permanently bonds the peeled
printed diecut label--encoded RFID transponder sandwich
(26/312).
[0135] Transponders which fail to verify may be either (1) attached
to "void" printed labels as described above, (2) recaptured while
still on the inlay carrier 318 by the inlay carrier take-up
mechanism 326, or (3) dispensed internally into a waste bin. The
latter 2 methods avoid wasting a label to eliminate a bad
transponder.
[0136] A still further embodiment for continuous linerless media
using active adhesives (i.e., where there is no diecut label
carrier 12) is shown in FIG. 24. Here, platen roller 20 and drive
roller 322 are both siliconized to prevent adherence of the label
and transponder adhesive to these rollers. The continuous linerless
label stock 350 is printed and an encode RFID transponder 312
attached in a manner similar to the above embodiment. However, once
a completed label is dispensed to media exit 30, as shown, then an
optional electrically activated cutter assembly 352 is used to
shear the finished linerless label 354 with or without attached
encoded RFID transponder 312. The continuous linerless label stock
350 is then retracted to its initial printing position under
printhead 18.
[0137] When an inactivated adhesive is used (such as an Appleton
Actifuse liner material), then an optional retractable activating
mechanism 356 may be used to activate the adhesive along the length
of the finished linerless label 354 retracted for the length of the
excess media, which must be dispensed to bring the finished
linerless label 354 to the cut off point. Otherwise, the embodiment
functions as with standard linerless material as described
above.
[0138] From the foregoing, it will also be observed that numerous
modifications and variations can be effectuated by those skilled in
the art without departing from the true spirit and scope of the
novel concepts of the present invention. It is to be understood
that no limitation with respect to the specific embodiments
illustrated is intended or should be inferred. The disclosure is
intended to cover by the appended claims all such modifications as
fall within the scope of the claims when the claims are properly
interpreted.
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