U.S. patent application number 11/660304 was filed with the patent office on 2007-11-08 for radio frequency identification (rfid) label applicator.
This patent application is currently assigned to Sensormatic Electronics Corporation. Invention is credited to John C. Ford, Christopher Marcus.
Application Number | 20070257798 11/660304 |
Document ID | / |
Family ID | 35414956 |
Filed Date | 2007-11-08 |
United States Patent
Application |
20070257798 |
Kind Code |
A1 |
Ford; John C. ; et
al. |
November 8, 2007 |
Radio Frequency Identification (Rfid) Label Applicator
Abstract
The invention relates to an RFID label applicator that may
include a peeler body portion having a peel end, the body portion
being configured to cause an RFID label to peel away from a web
when the web passes around the peel end. The body portion may
define a cavity having an RFID programming antenna located therein
that is configured to transmit programming signals to the RFID
label prior to its passing around the peel end. The system may also
include an extendable path altering mechanism configured to advance
from a retracted position to an extended position to alter a path
of the web around said peel end, and wherein the extendable path
altering mechanism is positioned and dimensioned to inhibit a RFID
label from peeling away from the web when in the extended
position.
Inventors: |
Ford; John C.; (Boca Raton,
FL) ; Marcus; Christopher; (Simpsonville,
SC) |
Correspondence
Address: |
IP LEGAL DEPARTMENT;TYCO FIRE & SECURITY SERVICES
ONE TOWN CENTER ROAD
BOCA RATON
FL
33486
US
|
Assignee: |
Sensormatic Electronics
Corporation
6600 Congress Avenue
Boca Raton
FL
33487
|
Family ID: |
35414956 |
Appl. No.: |
11/660304 |
Filed: |
August 29, 2005 |
PCT Filed: |
August 29, 2005 |
PCT NO: |
PCT/US05/30957 |
371 Date: |
February 12, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60604930 |
Aug 27, 2004 |
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60605035 |
Aug 27, 2004 |
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60604931 |
Aug 27, 2004 |
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60604929 |
Aug 27, 2004 |
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Current U.S.
Class: |
340/572.1 |
Current CPC
Class: |
B65C 2009/0003 20130101;
G08B 13/2417 20130101; B65C 9/1884 20130101; Y10T 156/1707
20150115; B65C 2009/0093 20130101; B65C 2009/405 20130101 |
Class at
Publication: |
340/572.1 |
International
Class: |
G08B 13/14 20060101
G08B013/14 |
Claims
1. An applicator peeler member for programming a radio frequency
identification (RFID) label, wherein said RFID label contains an IC
chip to be programmed, said peeler member comprising: a body
portion including a peel end, said body portion being configured to
cause said RFID label to peel away from a web when said web passes
around said peel end, said body portion defining a cavity; and an
RFID programming antenna located within said cavity in said body
portion, said RFID programming antenna being configured to transmit
programming signals to said IC chip in said RFID label on said web
prior to passing around said peel end.
2. The applicator peeler member of claim 1, further comprising a
cover over said cavity, wherein said cover includes a material that
allows said programming signals to pass through.
3. The applicator peeler member of claim 1, wherein said RFID
programming antenna is configured to be laterally adjustable within
said cavity.
4. The applicator peeler member of claim 1, further comprising an
extendable path altering mechanism integrated with said body
portion, said extendable end being configured to advance from a
retracted position to an extended position such that said
extendable path altering mechanism alters a path of said web around
said peel end, and wherein said extendable path altering mechanism
is positioned and dimensioned to inhibit a RFID label from peeling
away from said web when said extendable path altering mechanism is
in said extended position.
5. The applicator peeler member of claim 4, wherein said extendable
end further comprises a tip having radial member for contacting
said web.
6. An RFID label applicator comprising: a peeler member including a
peel end, said peeler member being configured to cause an RFID
label to peel away from a web when said web passes around said peel
end of said peeler member; an extendable path altering mechanism
located proximate said peel end, said extendable path altering
mechanism being configured to advance from a retracted position to
an extended position such that said extendable path altering
mechanism alters a path of said web around said peel end, and
wherein said extendable path altering mechanism is positioned and
dimensioned to inhibit a RFID label from peeling away from said web
when said extendable path altering mechanism is in said extended
position; and a label tamp assembly, said label tamp assembly being
configured to receive said RFID label peeled away from said web and
to move said RFID label into contact with an item on which said
RFID label is to be applied.
7. The RFID label applicator of claim 6, wherein said peeler member
includes a cavity, and wherein said extendable path altering
mechanism is located in said cavity.
8. The RFID label applicator of claim 6, wherein said extendable
path altering mechanism comprises an extendable end and an end
driving mechanism coupled to said extendable end and configured to
move said extendable end from said retracted position to said
extended position.
9. The RFID label applicator of claim 8, wherein said extendable
end further comprises a tip having radial member for contacting
said web.
10. The RFID label applicator of claim 6, further comprising a RFID
programming system configured to program RFID labels prior to
passing around said peel end and to detect defective RFID labels,
and wherein said extendable path altering mechanism is configured
to move to said extended position in response to detection of a
defective RFID label.
11. The RFID label applicator of claim 10, wherein said RFID
programming system includes a RFID programming antenna integrated
into said peeler member.
12. A method of programming RFID labels, said method comprising:
advancing a web supporting RFID labels over a peeler member until
at least one of said RFID labels is positioned within a programming
range of a RFID programming antenna integrated with said peeler
member; transmitting programming signals from said RFID programming
antenna to an IC chip in said one of said RFID labels; and causing
said one of said RFID labels to peel away from said web as said web
passes around a peel end of said peeler member.
13. The method of claim 10, further comprising attempting to read
said RFID label to determine if said RFID label is defective.
14. The method of claim 10, further comprising rejecting a
defective one of said RFID labels.
Description
TECHNICAL FIELD
[0001] The present application relates to radio frequency
identification (RFID) label applicators, and more particularly, to
a RFID label applicator capable of programming RFID labels,
detecting defective RFID labels and rejecting the defective RFID
labels.
BACKGROUND INFORMATION
[0002] Radio frequency identification (RFID) systems are generally
known and may be used for a number of applications such as managing
inventory, electronic access control, security systems, automatic
identification of cars on toll roads, and electronic article
surveillance (EAS). RFID devices may be used to track or monitor
the location and/or status of articles or items to which the RFID
devices are applied. A RFID system typically comprises a RFID
reader and a RFID device such as a tag or label. The RFID reader
may transmit a radio-frequency carrier signal to the RFID device.
The RFID device may respond to the carrier signal with a data
signal encoded with information stored on the RFID device. RFID
devices may store information such as a unique identifier or
Electronic Product Code (EPC) associated with the article or
item.
[0003] RFID devices may be programmed (e.g., with the appropriate
EPC) and applied to the article or item that is being tracked or
monitored. A RFID reader/programmer may be used to program RFID
devices and to detect defective RFID devices. Label applicators
have been used to apply programmed RFID labels to items or
articles.
[0004] Existing RFID applicators, however, have encountered
problems in handling defective labels. In existing RFID
applicators, a RFID reader/programmer may be located upstream from
the applicator. One problem occurs when tracking a defective label
from the point at which it is detected to the point at which it can
be rejected. Because of potential differences in the RFID label
footprints and web paths through the applicator, the number of
labels between the point of detection and the point of rejection
may be inconsistent. As a result of this inconsistency, an
applicator may reject a good label and may apply a defective label
to the product.
[0005] Another problem is that the rejection of defective RFID
labels may interrupt the label application process and may result
in labels not being applied to items or products. When a defective
label is detected using conventional techniques, it may be removed
from the process and another label may be re-encoded in its place.
Each defective label that is encountered may cut the product
application rate by up to an additional 50%. Product lines may need
to be run slower so as not to miss a product in the event a
defective label is detected.
SUMMARY OF THE INVENTION
[0006] The invention relates to an RFID label applicator.
Embodiments of the invention may include a peeler body portion
having a peel end, the body portion being configured to cause an
RFID label to peel away from a web when the web passes around the
peel end. The body portion may define a cavity having an RFID
programming antenna located therein that is configured to transmit
programming signals to the RFID label prior to its passing around
the peel end. The system may also include an extendable path
altering mechanism configured to advance from a retracted position
to an extended position to alter a path of the web around said peel
end, and wherein the extendable path altering mechanism is
positioned and dimensioned to inhibit a RFID label from peeling
away from the web when in the extended position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The subject matter regarded as the embodiments is
particularly pointed out and distinctly claimed in the concluding
portion of the specification. The embodiments, however, both as to
organization and method of operation, together with objects,
features, and advantages thereof, may best be understood by
reference to the following detailed description when read with the
accompanying drawings in which:
[0008] FIG. 1 is a diagrammatic view of a RFID applicator,
consistent with one embodiment of the invention.
[0009] FIG. 2 is a side cross-sectional view of one embodiment of a
RFID label that can be used in the RFID applicator, consistent with
one embodiment of the invention.
[0010] FIG. 3 is a side view of one embodiment of a RFID applicator
peeler member with an integrated RFID programming antenna.
[0011] FIGS. 4A-4C are side views of one embodiment of a label
reject assembly in various positions with respect to a RFID
applicator peeler member for use in a RFID applicator.
[0012] FIGS. 5A and 5B are side views of another embodiment of a
label reject assembly integrated into a RFID applicator peeler
member for use in a RFID applicator.
[0013] FIG. 6A is a side view of one embodiment of a label tamp
assembly.
[0014] FIG. 6B is a top view of the label tamp assembly shown in
FIG. 6A.
[0015] FIG. 7A is a bottom view of one embodiment of a vacuum tamp
pad that may be used in a label tamp assembly.
[0016] FIG. 7B is a cross-section view of the vacuum tamp pad shown
in FIG. 7A taken along line A-A.
[0017] FIG. 7C is a side view of the vacuum tamp pad shown in FIG.
7A.
[0018] FIG. 8A is a side view of another embodiment of a vacuum
tamp pad for use in a RFID applicator.
[0019] FIG. 8B is a bottom view of the vacuum tamp pad shown in
FIG. 8A.
DETAILED DESCRIPTION
[0020] Numerous specific details may be set forth herein to provide
a thorough understanding of the embodiments of the disclosure. It
will be understood by those skilled in the art, however, that
various embodiments of the disclosure may be practiced without
these specific details. In other instances, well-known methods,
procedures, components and circuits have not been described in
detail so as not to obscure the various embodiments of the
disclosure. It can be appreciated that the specific structural and
functional details disclosed herein are representative and do not
necessarily limit the scope of the disclosure.
[0021] It is worthy to note that any reference in the specification
to "one embodiment" or "an embodiment" according to the present
disclosure means that a particular feature, structure, or
characteristic described in connection with the embodiment is
included in at least one embodiment. The appearances of the phrase
"in one embodiment" in various places in the specification are not
necessarily all referring to the same embodiment.
[0022] Referring to FIG. 1, radio frequency identification (RFID)
label applicator 100, consistent with embodiments of the invention,
may be used to apply RFID labels 102 to articles or items 104. The
RFID label applicator 100 may also be used to program RFID labels
102, to detect defective RFID labels, and to reject the defective
labels such that the defective labels are not applied to the items
104. The articles or items 104 may be products, merchandise, or any
other items or articles that may be monitored using RFID
techniques.
[0023] The RFID labels 102 may be removably secured to a backing
material or web 110 such that the RFID labels 102 are supported on
the web 110 during programming and may be removed (e.g., peeled
away from the web 110) for application. The web 110 supporting the
labels 102 may be rolled onto a roll 112, which is unwound to allow
the web 110 to pass through the label applicator 100. After the
RFID labels 102 are removed or rejected, scrap web 110a may be
rewound onto a rewind roll 114.
[0024] One embodiment of the RFID label applicator 100 may include
a web feeding mechanism 120 to feed the web 110, a RFID programming
system 130 to program the RFID labels 102, a peeler member 140 to
peel the RFID labels 102 from the web 110, a label tamp assembly
150 to apply the RFID labels 102 to the items 104, and a label
reject assembly 160 to reject RFID labels. The RFID label
applicator 100 may also include an applicator controller 170 to
control operation of the RFID label applicator 100. The articles or
items 104 may be arranged in a line (e.g., a product line) and may
be moved, for example, using a conveyor 180 or other similar
mechanism. Components in the applicator 100 may be mounted or
secured to an applicator frame 108.
[0025] The RFID label applicator 100 may also include other
components not shown in FIG. 1. Examples of additional components
include, but are not limited to, a label sensor to sense and
position the labels 102 relative to the RFID programming system
130, an item sensor to sense and position the items 104 relative to
the tamp assembly 150, and an integrated printer to print indicia
on the labels 102. One example of a label sensor includes a
thru-beam that shines a light from beneath the web to a light
sensor 110 positioned above the web 110.
[0026] The web feeding mechanism 120 may include a tensioning
roller 122 and an idler roller 124, which guide the web 110 with
the RFID labels 102 to the peeler member 140. The web feeding
mechanism 120 may also include a drive and nip roller assembly 126
that takes up the scrap web 110a and feeds the scrap web 110a to
the web rewind roll 114. The drive and nip roller assembly 126 may
be driven to pull the scrap web 110a, thereby causing the web 110
with the RFID labels 102 to pass around the peeler member 140. The
unwind roll 112 and/or rewind roll 114 may also be driven (e.g.,
with servomotors) to facilitate unwinding of the web 110 and/or
rewinding the scrap web 110a.
[0027] The RFID programming system 130 may include a RFID
reader/programmer coupled to one or more RFID programming antennas,
as will be described in greater detail below. The RFID programming
system 130 may include any RFID reader/programmer known to those
skilled in the art for reading and/or programming RFID devices,
such as the type known as the Sensormatic.RTM. SensorID.TM. Agile 2
Reader available from Tyco Fire and Security. The RFID programming
system 130 may also be capable of detecting defective RFID labels,
for example, by attempting to read a RFID label after applying
programming signals.
[0028] The peeler member 140 may include a peel tip 142 having a
radius and forming an angle such that a RFID label 102 peels away
from the web 110 as the web 110 passes around the peel tip 142. In
one embodiment, the radius of the peel tip 142 may be in a range of
about 0.030 in. and the angle formed by the peel tip 142 may be in
a range of about 90.degree. or less. Other radii and angles are
within the scope of the invention and may depend upon the adhesion
properties (e.g., the adhesion strength) of the RFID labels 102 on
the web 110. The peeler member 140 may be made of a rigid material
such as aluminum. In one embodiment, the peeler member 140 may be
in the form of a plate or a bar, although those skilled in the art
will recognize other shapes and configurations.
[0029] The label tamp assembly 150 may include a tamp pad 152
coupled to a tamp driving mechanism 154. The tamp pad 152 contacts
the non-adhering side of a RFID label 102a that has been removed
from the web 110 and holds the RFID label 102a. The tamp driving
mechanism 154 drives the tamp pad 152 and the RFID label 102a
toward the item 104 to which the RFID label 102a is to be applied.
One embodiment of the tamp assembly 150 uses a vacuum pressure to
retain the RFID label 102a in contact with the tamp pad 152. The
vacuum pressure may be released and/or air may be blown from the
tamp pad 152 to facilitate application of the RFID label 102a.
Although one embodiment of a label tamp assembly 150 is described
herein, the label tamp assembly 150 may include any structure or
mechanism for moving a label into contact with an item 104.
[0030] The label reject assembly 160 may include an accumulation
pad 162 coupled to a label reject driving mechanism 164. Upon
determining that a RFID label 102 is to be rejected, the reject
driving mechanism 164 drives the accumulation pad 162 into the path
of the tamp pad 152. The tamp pad 152 then applies the rejected
RFID label to the accumulation pad 162 instead of the item 104. A
RFID label may be rejected when the label is determined to be
defective or for other reasons. Although one embodiment of the
label reject assembly 160 is described herein, the label reject
assembly 160 may include any structure for intercepting or
otherwise preventing a RFID label from being applied to an item
104.
[0031] The tamp driving mechanism 154 and the label reject driving
mechanism 164 may include pneumatic actuated air cylinders, such as
the type available from PHD, Inc. When air cylinders are used as
the driving mechanisms, the RFID label applicator 100 may also
include one or more air pressure gauges 168 to monitor and/or
adjust operation of the air cylinders, as is known to those skilled
in the art. Although the described embodiment uses air cylinders
and rods, those skilled in the art will recognize that other linear
actuators or driving mechanisms may be used.
[0032] The applicator controller 170 may be a programmable logic
controller (PLC), such as the type available from Allen-Bradley,
Omron or Mitsubishi, or a general purpose computer, such as a PC,
programmed to control one or more operations of the applicator 100.
The controller 170 may be coupled to the web feeding mechanism 120
(e.g., to the motors, sensors, etc.) to control the feeding of the
web 110 around the peeler member 140 and/or to control the
positioning of the RFID labels 102 relative to the RFID programming
system 130. The controller 170 may also be coupled to the tamp
assembly 150 to control application (or tamping) of programmed and
removed RFID labels to the items 104. The controller 170 may also
be coupled to the label reject assembly 160 to control the
rejection of labels, for example, when the label is determined to
be defective. The controller 170 may also be coupled to a user
interface/control panel 172 to enable a user to monitor the
application process and/or to provide commands and/or operating
parameters to the controller 170.
[0033] The controller 170 and/or user interface 172 may also be
coupled to the RFID programming system 130 to control the RFID
programming operations. RFID programming operations may be
controlled, for example, by allocating Electronic Product Codes
(EPC's) and/or other data to be sent to the RFID labels 102 upon
receiving an indication that the RFID labels 102 are properly
positioned relative to the RFID programming system 130. The
controller 170 may also monitor the detection of defective labels
to control the label reject assembly 160. The controller 170 may
further collect programming data and statistics and provide such
data to the user.
[0034] According to one method of operation, the web 110 may be
advanced around the peeler member 140, for example, by using the
drive and nip roller assembly 126 to pull the web 110. As the web
110 is advanced, the unwind roll 112 unwinds the web 110 supporting
the RFID labels 102 and the rewind roll 114 rewinds the scrap web
110a after the RFID labels 102 have been applied or rejected. When
each RFID label 102 on the web 110 is positioned within a
programming range of the RFID programming system 130, the RFID
programming system 130 may program the RFID label 102 by
transmitting radio frequency (RF) programming signals to the RFID
label 102 and attempting to read the RFID label 102. The RFID label
102 may then be advanced around the peel tip 142 of the peeler
member 140 to remove the RFID label 102. A removed RFID label 102a
may then be applied to an item 104 using the tamp assembly 150 or
may be rejected using the label reject assembly 160. These
operations may be repeated for each of the RFID labels 102 on the
web 110 and the items 104 may be advanced such that programmed RFID
labels 102 are applied to each of the items 104.
[0035] One embodiment of a RFID label 102 is shown in greater
detail in FIG. 2. The RFID label 102 may include an integrated
circuit (IC) chip 202 coupled to an antenna 204. The IC chip 202
and antenna 204 may be sandwiched between one or more layers or
substrates, such as an adhesive substrate 206 and a printable layer
208. The adhesive substrate 206 may include a scrim coated on each
side with an adhesive, such as an acrylic based adhesive. The
printable layer 208 may be made of a thermal transfer paper or
other material suitable for printing. One or more additional layers
or substrates may also be incorporated into the RFID label 102, as
is known to those skilled in the art. The web 110 may be made of a
paper with a release agent such as wax or silicone to allow the
RFID label 102 to peel away from the web 110. The RFID label 102
may have a peel adhesion strength (e.g., about 15 N/inch) that
allows the RFID label 102 to be removably adhered to the web 110
and later adhered to the items 104. Although RFID labels may have
various sizes, one example of the RFID label 102 may be about 3 in.
by 3 in. and supported on a web 110 having a width of about 4
in.
[0036] One example of a RFID label 102 is the "Combo EAS/RFID Label
or Tag" disclosed in U.S. Provisional Patent Application Ser. No.
60/628,303, which is fully incorporated herein by reference. Other
examples include the RFID labels commercially available under the
name Sensormatic.RTM. from Tyco Fire and Security. Those skilled in
the art will recognize that the RFID label 102 may include any RFID
device capable of being adhered or otherwise secured to articles or
items.
[0037] Referring to FIG. 3, one embodiment of a peeler member 140a
is described in greater detail. The peeler member 140a may include
a RFID programming antenna 132 integrated with the peeler member
140 and connected to a RFID reader/programmer 134. Each RFID label
102 may thus be programmed and verified just before peeling the
label and transferring the label to the tamp pad 152 (see FIG. 1).
The proximity of the RFID programming antenna 132 to the peel tip
142 allows each defective RFID label to be handled immediately
(i.e., without having to track defective labels from a point of
detection to a point of application further downstream), which may
ensure that defective labels are subject to rejection and
programmed labels are applied to items.
[0038] According to one embodiment, the RFID programming antenna
132 may be a near-field probe such as the type disclosed in U.S.
Provisional Patent Application Ser. No. 60/624,402, which is fully
incorporated herein by reference. The programming range of a
near-field probe is generally the near-field zone of the antenna or
probe. The near field probe may be implemented by enhancing the
magnitude of the induction field within the near-near field zone
associated with an antenna structure and decreasing the magnitude
of the radiation field within the far-field zone associated with
the antenna structure. One embodiment of the near field probe may
include a stripline antenna terminated into a 50 ohm chip resistor.
In one example, the near field probe may have an operating
frequency of 915 MHz and the near-field zone may be approximately 5
cm from the probe. One example of the probe may be about 2 to 3 in.
long, although those skilled in the art will recognize that smaller
probes may be used to allow programming of labels that are smaller
and/or spaced closer together on the web.
[0039] This embodiment of the peeler member 140a may include a
cavity 302 in a body portion 304 of the peeler member 140a, which
is configured to receive the RFID programming antenna 132. A cover
306 may be used to cover the cavity 302. The cover 306 may be made
of, or at least coated with, a non-reflective material that will
not reflect or absorb the radio frequency waves transmitted by the
RFID programming antenna 132 and the RFID device antenna 204. For
example, the cover 306 may be made of a plastic material such as
the type available under the name Delrin.TM.. A cable 308 may
connect the RFID programming antenna 132 to the RFID
reader/programmer 134. The cable 308 may extend from the RFID
programming antenna 132 through one side 310 of the body portion
304 of the peeler member 140a.
[0040] The RFID programming antenna 132 may be positioned within
the cavity 302 such that the RFID programming antenna 132 transmits
radio frequency (RF) programming signals to a RFID label 102b
positioned over the RFID programming antenna 132 (i.e., within the
programming range). The cavity 302 may include an adjustment region
312 that allows the RFID programming antenna 132 to be adjusted
laterally within the cavity 302 to accommodate different sizes of
labels. For example, the RFID programming antenna 132 may be
configured initially to align with the IC in labels having a
certain size (e.g., 3 in. by 3 in.) and may need to be adjusted
laterally for labels that are smaller or larger. In one example,
the lateral adjustment of a probe having a length of about 2 to 3
in. may be in a range of about 1 to 1.5 inches in either direction.
An adjustment mechanism, such as a bar or rod 320, may be coupled
to the RFID programming antenna 132 to provide mechanical
adjustment.
[0041] Although the described embodiment shows the RFID programming
antenna 132 located inside of the cavity 302 in the peeler member
140a, the RFID programming antenna 132 may also be integrated with
the peeler member 140a in other ways. For example, the RFID
programming antenna 132 may be mounted anywhere such that an RFID
label 102b on the peeler member 140a is within the programming
range (e.g., the near field) of the programming antenna 132.
[0042] According to one method of programming RFID labels, the web
110 may be advanced along the peeler member 140a until a RFID label
102b is positioned within a programming range of the RFID
programming antenna 132. The RFID label 102b may be positioned, for
example, by stopping advancement of the web 110 when a label sensor
(not shown) senses an edge of the RFID label 102b. When positioned,
RF programming signals may be transmitted to the RFID label 102b
from the RFID programming antenna 132. RF signals may also be
transmitted from the RFID label 102b to the RFID programming
antenna 132 in an attempt to read and validate the RFID label 102b.
If the RFID label 102b cannot be read or validated, the RFID
reader/programmer 134 may indicate that the RFID label 102b is
defective. After the RFID label 102b is either programmed or
determined to be defective, the web 110 is advanced along the
peeler member 140a until the next RFID label 102 is located in the
programming range of the RFID programming antenna 132.
[0043] A programmed RFID label 102a may be subsequently removed as
the web 110 supporting the programmed RFID label 102a passes around
the peel tip 142. In this described embodiment, the programmed RFID
label 102a is removed when the next RFID label 102b is positioned
in the programming range. The next RFID label 102b may be
programmed after the programmed RFID label 102a is applied to an
item or may be programmed while the programmed RFID label 102a is
applied to an item.
[0044] Referring to FIGS. 4A-4C, one embodiment of the label reject
assembly 160 is described in greater detail. The accumulation pad
162 may include at least a substrate that is sufficiently rigid to
receive and adhere to a rejected RFID label applied by the tamp pad
152. The reject driving mechanism 164 may be mounted in any
location that enables the accumulation pad 162 to be driven into a
path 400 of the tamp apply stroke (i.e., between the tamp pad 152
and the item 104) and then withdrawn such that the tamp pad 152
will clear the accumulation pad 162 and the rejected label(s) on
the accumulation pad 162.
[0045] The accumulation pad 162 may be configured to receive
multiple rejected RFID labels stacked on previous rejected labels.
The accumulation pad 162 may also be configured to receive rejected
labels adjacent to other rejected labels (e.g., multiple adjacent
stacks). The accumulation pad 162 may be sized according to the
size of the labels and the manner in which the labels are
accumulated (e.g., one stack or adjacent stacks) on the
accumulation pad. For example, an accumulation pad 162 may have a
size that is capable of adhering to and receiving at least one
label or may have a size that is capable of receiving multiple
adjacent stacks of labels.
[0046] The accumulation pad 162 may include a low surface energy
medium, such as polytetrafluoroethylene, at least on the surface of
the accumulation pad 162, which allows the accumulated RFID
label(s) to be easily removed by peeling away the bottom label. The
accumulation pad 162 may also include a removable layer, such as an
index card material, to allow the accumulated RFID label(s) to be
removed.
[0047] According to one method of rejecting RFID labels, the RFID
labels 102 on the web 110 may be programmed prior to passing the
web 110 around the peel tip 142 of the peeler member 140, for
example, as described above. Programming the RFID labels may
include detecting any defective RFID labels that should be
rejected. A RFID label 102a that is properly programmed may be
removed and applied to an item (FIGS. 4A and 4B). Upon detecting a
defective RFID label 102c, the label accumulation pad 162 may be
extended from a retracted position (FIGS. 4A and 4B) to an extended
position (FIG. 4C) into the path 400 between the tamp pad 152 and
the item 104. In the extended position, the label accumulation pad
162 prevents a full tamp apply stroke down to the item 104 and thus
intercepts the rejected RFID label 102c before the rejected RFID
label 102c is applied to an item 104. The tamp pad 152 may apply
the rejected RFID label 102c to the accumulation pad 162 in the
same manner as applying labels to items 104, as described in
greater detail below. The accumulation pad 162 with the rejected
RFID label(s) 102c applied thereto may then be retracted and normal
label application may continue.
[0048] The accumulation pad 162 may also be extended to different
positions within the path 400 of the tamp apply stroke such that
labels are received on the accumulation pad 162 adjacent to other
labels. The controller 170 may control the reject driving mechanism
164 to control positioning of the accumulation pad 162 such that
labels are positioned in an organized fashion (e.g., spread evenly)
on the accumulation pad 162.
[0049] The accumulated rejected RFID labels may be removed from the
accumulation pad 162 after a number of rejected labels accumulate
on the accumulation pad 162. The number of accumulated rejected
labels may be monitored. According to one method, a numeric reject
number may be printed (e.g., using an integrated printer) on the
surface of a rejected label 102c and a reject label counter (e.g.,
in the controller 170) may be incremented. The controller 170 may
provide an indication to the user as to when the accumulated labels
should be removed. When the stack of accumulated labels is removed,
the last numeric reject number on the top accumulated label will
signify the sum of the accumulated labels in the stack, for
customer recording purposes.
[0050] In one embodiment, about twenty (20) to thirty (30) labels
may be accumulated on the accumulation pad 162 before removing the
labels. One embodiment of the RFID label applicator 100 may have a
label programming failure rate of about 5%. In other words, about 5
out of every 100 RFID labels may be rejected as defective, which
allows about 400 to 600 RFID labels to be applied before the stack
of accumulated labels is removed. The label reject assembly 160
thus allows labels, such as defective RFID labels, to be rejected
(i.e., not applied to an item 104) with minimal or no interruption
to the label application process. Alternatively, a rejected RFID
label may be removed from the accumulation pad 162 after each
rejected label is intercepted by the accumulation pad 162.
[0051] An alternative embodiment of a label reject assembly may
include the extendable path altering mechanism 500 shown in FIGS.
5A and 5B. The extendable path altering mechanism 500 is extendable
from a retracted position (FIG. 5A) to an extended position (FIG.
5B). In the extended position, the extendable path altering
mechanism 500 may alter a path of the web 110 around the peel tip
142, effectively enlarging the radius of the peel tip 142. As a
result, a rejected RFID label 102d passing around the peel tip 142
does not peel away from the web 110 and continues moving with the
scrap web 110a instead of being applied to an item. Rejected RFID
labels, such as defective RFID labels, may thus be handled
automatically with minimal or no effect on the application
process.
[0052] The extendable path altering mechanism 500 may include an
extendable tip 502 coupled to a tip driving mechanism 504. The
extendable tip 502 may be rounded with a larger radius than the
peel tip 142. In one example, the radius of the extendable tip 502
may be in a range of about 0.25 to 0.5 in. The extendable tip 502
may be made of plastic, aluminum or other suitable material that
allows the web 110 to slide around the extendable tip 502. The tip
driving mechanism 504 may include a pneumatic actuated air
cylinder, although those skilled in the art will recognize that
other linear actuators or driving mechanisms may be used.
[0053] In one embodiment, the extendable path altering mechanism
500 may be integrated with another embodiment of the peeler member
140b. The peeler member 140b may include a cavity 510 for receiving
the extendable path altering mechanism 500. Alternatively, the
extendable path altering mechanism 500 may be located adjacent to
the peeler member 140b as long as the extendable tip 502 can extend
to alter the path of the web 110 in a manner that will prevent a
label from peeling away. The peeler member 140b may also include
the RFID programming antenna 132 integrated with the peeler member
140b, for example, as described above.
[0054] According to one method of rejecting RFID labels using the
extendable path altering mechanism 500, a RFID label 102b on the
web 110 may be programmed prior to passing the RFID label around
the peel tip 142 of the peeler member 140b, for example, using the
integrated RFID programming antenna 132. Programming the RFID label
102b may include detecting whether or not the RFID label 102b is
defective, e.g., by attempting to read information programmed
thereon. A RFID label 102a that is properly programmed is caused to
peel away from the web 110 as the web 110 and the RFID label 102a
passes around the peel tip 142 of the peeler member 140b. Upon
detecting a defective RFID label 102d, the path of the web 110
around the peel tip 142 may be altered using the extendable path
altering mechanism 500, for example, by extending the extendable
tip 502 beyond the peeler tip 142. When the extendable tip 502 is
extended, the web 110 may be advanced to position the next RFID
label 102 for programming and/or application and the rejected RFID
label 102d passes around the extendable tip 502 and remains on the
scrap web 110a instead of being applied to the tamp pad 152. The
extendable tip 502 may then be retracted and normal label
application may continue.
[0055] To allow the path of the web 110 to be altered, the tension
in the web 110 may be released such that the scrap web 110a unwinds
and the position of the RFID label 102b can be maintained on the
peeler member 140b. The tension in the web 110 may be released, for
example, by releasing a torque brake on a motor driving the web
rewind roll and/or releasing the drive and nip roller assembly.
[0056] Referring to FIGS. 6A and 6B, another embodiment of the tamp
assembly 150a is described in greater detail. The tamp assembly
150a may include a vacuum tamp pad 600 coupled to an air manifold
602. The vacuum pad 600 may include one or more vacuum holes 610
extending through the vacuum pad 600 to a label contacting side
612. The manifold 602 may include an inlet/outlet 620 and at least
one air chamber 622 located over the vacuum holes 610 in the vacuum
pad 600. The inlet/outlet 620 may be coupled to an air supply or
compressor, which may be switched between compressed air and a
vacuum. When a vacuum is applied, air may be drawn through the
inlet/outlet 620 and the chamber 622 in the manifold 602, which
causes air to be drawn through the vacuum holes 610 in the vacuum
pad 600. As a result, a vacuum pressure is generated around the
vacuum holes 602 on the label contacting side 612 of the vacuum pad
600, which is sufficient to hold the label 102 against the vacuum
pad 600.
[0057] As shown in FIGS. 7A-7C, the vacuum tamp pad 600 may include
slots or channels 614 extending along the label contacting side 612
to promote air discharge when the vacuum is drawn. The slots or
channels 614 may also provide for less friction against a label
when transferring the label to the tamp pad 600 (e.g., in the label
feed direction 604). The vacuum tamp pad 600 may also include a
relief area 616 configured to receive the portion of the RFID label
with the IC chip. The relief area 616 protects the IC chip from
stresses due to abrasion during label transfer to the pad 600 and
protects the IC chip from compressive stresses during tamp
placement of the RFID label onto an item or product. The vacuum
tamp pad 600 may further include a chamfer 618 at a leading edge
617 of the vacuum tamp pad 600 to promote easy label transfer to
the tamp pad 600, as the label moves in the label feed direction
604 from the peeler member.
[0058] The embodiment of the vacuum tamp pad 600 shown in FIGS.
7A-7C is designed for a 3 in..times.3 in. RFID label. For this
example, the vacuum pad 600 may have a length l of about 3.125 in.,
a width w of about 3.00 in. and a thickness t of about 0.25 in. The
tamp pad 600 may be made of a plastic material, such as the type
available under the name Delrin, or other suitable materials.
[0059] This described embodiment of the vacuum pad 600 includes
four (4) vacuum holes 610a-610d. The vacuum holes 610a-610d may be
located to minimize the effect of label bow or curl and to allow
each of the vacuum holes 610a-610d to be sealed regardless of the
amount of label bow, thereby effectively holding the label on the
vacuum pad 600. For example, the holes 610a and 610c may be located
in from the leading edge 617 about 1/4 of the length of the vacuum
pad 600 and the holes 610b and 610d may be located in from the
leading edge 617 about 3/4 of the length of the vacuum pad 600. The
holes 610a and 610b may be located in from the side edge 619 about
1/3 of the length of the vacuum pad 600 and the holes 610c and 610d
may be located in from the side edge 619 about 2/3 of the length of
the pad 600. The holes 610a-610d may have a diameter of about
0.093''.
[0060] The vacuum pad 600 and/or manifold 602 may be mounted to a
mounting block 630 with one or more compression springs 632
positioned therebetween (FIG. 6A). The compression springs 632 may
compress as needed when the vacuum tamp pad 600 contacts a product,
allowing the tamp pad 600 to mate parallel with a surface of an
item or product to which a label is being applied. The mounting
block 630 may include tapered holes 634 that receive shoulder bolts
636, which secure the compression springs 632 and allow the
compression springs 632 to compress. Although the described
embodiment shows four (4) compression springs 632, any number of
compression springs may be used to provide the desired compression,
as may be determined by one of ordinary skill in the art.
[0061] A proximity sensor 640 may also be mounted to the manifold
602 or to the vacuum tamp pad 600 to detect the surface of the item
or product to which the label is to be applied. The proximity
sensor 640 may thus enable consistent compression of the
compression springs 632 when labels are being applied to items or
products having surfaces at different levels.
[0062] The tamp assembly 150 may also include a cylinder 650, such
as a pneumatic actuated air cylinder, and rod 652 for providing the
linear driving force. A cylinder mounting block 654 may be used to
mount the mounting block 630 to the rod 652. Those skilled in the
art will recognize that other linear actuators or driving
mechanisms may also be used.
[0063] According to an alternative embodiment, shown in FIGS. 8A
and 8B, a vacuum tamp pad 800 may include only three vacuum holes
810a-810c. A manifold 802 with an inlet/outlet 820 may be coupled
to the tamp pad 800 to cause air to pass through the vacuum holes
810a-810c. The vacuum holes 810a-810c may be positioned such that
the leading portion of a RFID label 102 is secured by the vacuum
force when the RFID label 102 is properly positioned. The trailing
portion of the RFID label 102 may be left free (i.e., not subject
to a vacuum) to relieve bow in the label 102. The vacuum hole 810c
near the far edge of the RFID label 102 may act as a label stop.
The vacuum holes 810a-810c thus take into account the natural bow
that is inherent to RFID labels that are provided in roll
format.
[0064] A fixed stop 808 may be positioned adjacent the vacuum pad
800 to allow the label to feed (i.e., in the feed direction 804)
and orient properly. When the RFID label 102 is being fed to the
side of an item (e.g., a box) at a 90 degree angle relative to a
vertical plane (i.e., sideways), the fixed stop 808 may prevent a
gravity force 806 from misaligning the RFID label 102 with respect
to the vacuum pad 800. The fixed stop 808 may be fixed (e.g.,
bolted) to a bottom side of the tamp driving mechanism or
cylinder.
[0065] The vacuum holes 810a-810c may also be positioned to hold
the RFID label 102 in place without subjecting the IC chip 202 in
the RFID label 102 to vacuum forces at the holes 810a-810c. The
vacuum pad 800 may also be recessed (not shown) in the area
receiving the IC chip 202 to provide additional relief. The vacuum
pad 800 may also include a compressible material, to avoid damage
to the IC chip 202 in the RFID label 102.
[0066] While the principles of the invention have been described
herein, it is to be understood by those skilled in the art that
this description is made only by way of example and not as a
limitation as to the scope of the invention. Other embodiments are
contemplated within the scope of the invention in addition to the
embodiments shown and described herein. Modifications and
substitutions by one of ordinary skill in the art are considered to
be within the scope of the invention, which is not to be limited
except by the following claims.
* * * * *