U.S. patent application number 12/380887 was filed with the patent office on 2009-09-24 for electronic data distribution system.
This patent application is currently assigned to Nextreme L.L.C.. Invention is credited to Scott A. W. Muirhead.
Application Number | 20090237222 12/380887 |
Document ID | / |
Family ID | 44650638 |
Filed Date | 2009-09-24 |
United States Patent
Application |
20090237222 |
Kind Code |
A1 |
Muirhead; Scott A. W. |
September 24, 2009 |
Electronic data distribution system
Abstract
An apparatus has a communications device associated therewith.
In another aspect of the present invention, a pallet is made from
thermoformed polymeric sheets with an attached communications
device. A further aspect of the present invention provides a radio
frequency identification device attached to an apparatus. In still
another aspect of the present invention, a communications device is
incorporated into one or more sheets of a pallet or other container
prior to forming. Methods of making and using a thermoformed pallet
and container, having a communications device, are also
provided.
Inventors: |
Muirhead; Scott A. W.;
(Surrey, CA) |
Correspondence
Address: |
PRICE & ADAMS, P.C.
4135 BROWNSVILLE ROAD, P.O. BOX 98127
PITTSBURGH
PA
15227-0127
US
|
Assignee: |
Nextreme L.L.C.
|
Family ID: |
44650638 |
Appl. No.: |
12/380887 |
Filed: |
March 4, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11476434 |
Jun 28, 2006 |
|
|
|
12380887 |
|
|
|
|
11102221 |
Apr 8, 2005 |
|
|
|
11476434 |
|
|
|
|
09770097 |
Jan 24, 2001 |
6943678 |
|
|
11102221 |
|
|
|
|
60177383 |
Jan 24, 2000 |
|
|
|
Current U.S.
Class: |
340/10.51 ;
340/10.1 |
Current CPC
Class: |
B29C 65/18 20130101;
B29C 51/12 20130101; G08B 13/2434 20130101; B65D 19/0018 20130101;
B65D 2519/00338 20130101; B29C 66/545 20130101; G08B 13/244
20130101; Y10T 156/1049 20150115; B29C 51/02 20130101; B65D
2519/00034 20130101; B65D 2519/0094 20130101; B65D 2519/00562
20130101; B65D 2519/00442 20130101; B29C 51/162 20130101; B65D
2519/00268 20130101; B65D 2519/00139 20130101; Y10S 108/901
20130101; B29C 48/157 20190201; B65D 2519/00273 20130101; B29C
66/83411 20130101; Y10T 156/1062 20150115; Y10T 156/1051 20150115;
B29C 51/267 20130101; B29C 51/46 20130101; B29C 66/433 20130101;
B29C 2049/2497 20130101; B29L 2017/00 20130101; B65D 2519/00407
20130101; Y10T 156/109 20150115; B65D 2203/10 20130101; B29L
2031/7126 20130101; B65D 2519/00557 20130101; G08B 13/2417
20130101; B29C 48/08 20190201; B29C 66/71 20130101; B29L 2031/7178
20130101; B65D 2519/00288 20130101; B65D 2519/00412 20130101; G08B
13/2445 20130101; B29C 66/1122 20130101; B29C 66/543 20130101; B29C
66/96 20130101; B65D 2519/00318 20130101; B29C 48/15 20190201; B29C
66/4722 20130101; B29C 2791/001 20130101; B65D 2519/00437 20130101;
Y10T 156/1734 20150115; B29C 66/9672 20130101; G08B 13/2462
20130101; B29L 2031/7172 20130101; B65D 2519/00069 20130101; B29C
66/71 20130101; B29K 2075/00 20130101; B29C 66/71 20130101; B29K
2023/12 20130101; B29C 66/71 20130101; B29K 2023/06 20130101 |
Class at
Publication: |
340/10.51 ;
340/10.1 |
International
Class: |
G06K 7/00 20060101
G06K007/00 |
Claims
1. A system that provides electronic product data to a component of
an industrial control system comprising: a component that stores
electronic product data obtained from a Radio Frequency
Identification (RFID) tag in a structured format, the RFID tag is
affixed to a product; and an interface that provides the electronic
product data to an industrial controller, the interface utilizes a
Programmable Logic Controller (PLC) interface to read and write at
least one of an input, an output, a tag, a state, and a status
parameter to the industrial controller.
2. A system as set forth in claim 1 in which: said interface
utilizes industrial protocols to exchange the electronic data with
an application external to the industrial controller, and said
application external to the industrial controller is associated
with at least one of an Enterprise System (ERP), a Manufacturing
Execution System (MES), or a Machine Control System (MC).
3. A system that manages the exchange of electronic product data
with an industrial controller comprising: a RFID interface that
receives electronic product data; a processing component that
parses the electronic product data and groups related electronic
product data; and an interface component that provides the
electronic product data to an industrial controller, the interface
component utilizes a PLC interface to read and write at least one
of an input, an output, a tag, a state, and a status parameter to
the industrial controller.
4. A system as set forth in claim 3 in which: said RFID interface
utilizes a wire or wireless connection to receive the electronic
product data.
5. A method for conveying electronic product data to components in
an industrial control system comprising: receiving a subscription
from an entity within an industrial control system for electronic
product data; obtaining the electronic product data from an RFID
product tag through an RFID reader; formatting the electronic data
in a structured form; and conveying the formatted electronic
product data to the subscribing entity, the conveying utilizes a
PLC interface to read and write at least one of an input, an
output, a tag, a state, and a status parameter to the industrial
controller.
6. A method as set forth in claim 5 which includes: formatting the
electronic product data in at least one of an Electronic Product
Code, a logical reader identifier, a timestamp, a flag indicating
an RFID tag is with a coverage area, a product type, a date of
manufacture, a lot number, an associated case, an associated
pallet, or an associated container level.
7. A method as set forth in claim 5 which includes: utilizing an
RFID interface that receives the electronic product data from one
of an RFID reader, a server, or an RFID tag.
8. A method for distributing electronic product data to an
industrial control system comprising: receiving electronic product
data from one of an RFID reader and a server; filtering the
electronic data to mitigate duplicate data; processing the accepted
electronic product data to a format in accordance with the
industrial control system; storing the formatted electronic product
data; and conveying the stored electronic product data to a
component of the industrial control system component, the conveying
utilizes a PLC interface to read and write at least one of an
input, an output, a tag, a state, and a status parameter to the
industrial controller.
9. A method as set forth in claim 8 which includes: conveying the
stored electronic product data to a component that includes an
industrial controller.
10. A method as set forth in claim 8 which includes: conveying
electronic product data to an industrial control system that is at
least one of an Enterprise System (ERP), a Manufacturing Execution
System (MES), or a Machine Control System (MC).
11. A method as set forth in claim 8 which includes: conveying the
stored electronic product data to a component that receives a
subscription or request from the industrial control system
component.
12. A method as set forth in claim 11 which includes: conveying the
stored electronic product data to a component that receives a
subscription for electronic product data associated with RFID tags
that enter a coverage area of the RFID reader.
13. A method as set forth in claim 8 which includes: writing
industrial control system component information to an RFID tag
affixed to a product.
14. A method as set forth in claim 8 which includes: employing at
least one of statistics, probabilities, inferences, and classifiers
to facilitate electronic product data collection, filtering,
formatting, storage, or distribution to the industrial control
system component.
15. A system that facilitates electronic data distribution to an
industrial component comprising: means for obtaining electronic
data from one or more RFID readers or one or more RFID servers;
means for storing the electronic data in a structured format; and
means for conveying the stored one or more data to the industrial
component, the conveying utilizes a PLC interface to read and write
at least one of an input, an output, a tag, a state, and a status
parameter to the industrial controller.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/476,434 filed on Jun. 28, 2006, which
claims the benefit of U.S. patent application Ser. No. 11/102,221
filed on Apr. 8, 2005, which claims the benefit of U.S. patent
application Ser. No. 09/770,097 filed on Jan. 24, 2001, now U.S.
Pat. No. 6,943,678 issued Sep. 13, 2005, and U.S. Provisional
application No. 60/177,383, filed on Jan. 24, 2000. The disclosures
of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention generally relates to thermoformed apparatus
and, more particularly, to a polymeric pallet or container having a
communications device.
[0004] 2. Description of the Prior Art
[0005] The 48 inch by 40 inch. wood pallet is an integral part of
North America's distribution system, and is involved in one way or
another in the movement of a significant proportion of all goods
bought and sold. According to Material Handling Engineering,
(October 1999), page 16, the U.S. Forest Service estimates there
are 1.9 billion wooden pallets in America. Approximately 400
million new pallets are needed each year. 175 million of these are
pallets repaired for reuse by industry. Therefore, roughly 225
million new wooden pallets enter the supply chain each year. The
standard 48 inch by 40 inch wood pallet makes up a significant
proportion of the total number of wood pallets within the over-all
distribution system.
[0006] U.S. Forest Service researchers also found that 225 million
wooden pallets are sent to landfills each year. According to CHEP
Equipment Pooling Systems, the largest third party pallet leasing
company with 94 million wooden pallets, the average 48 inch by 40
inch wooden pallet weighs between 28 pounds and 65 pound at time of
manufacture (dry). These traditional wooden pallets range from 48
pounds to 110 pounds in weight (wet) at time of recycling or
disposal. Using these figures, approximately 17.8 billion pounds of
wood is deposited in landfills each year. APA, the Engineered Wood
Association, estimates that a standard 48 inch by 40 inch style
lumber stringer pallet has a three year life. The three year cost
for this style of wooden pallet is estimated to be $11.74. A three
year life is based on 15-24 trips per year. Conventional wooden
pallets have limited residual value at the end of their useful life
cycle.
[0007] According to the Grocery Manufacturers of America
(hereinafter "GMA"), the largest end-user of traditional 48 inch by
40 inch wooden pallets within the North American distribution
system, the current wooden pallet exchange system costs the
industry nearly $2 billion to operate in 1991. For example, the
trucking industry is unable to optimize semi trailer loading or
per-unit transportation costs because GMA style pallets are not
capable of true four-way entry. Drivers are required to exchange
loaded pallets for empty pallets after delivery, and because of
manual pallet handling injuries, workers compensation claims are
significant. Grocery distributors are unable to use automated
material handling equipment efficiently because unacceptable wooden
pallets must be removed from the pallet supply chain. Grocery
manufacturers and shippers experience product damage because of
design flaws in traditional wooden pallets. Furthermore, unit
loading is not evenly distributed with stringer pallet designs,
which results in product and packaging damaged in transport.
Manufacturers must use stronger and costlier packaging because of
wooden pallet problems. Wooden pallet sanitation and moisture
absorption difficulties affect meat and other food processors.
Moreover, general pallet deterioration, manifested by protruding
nails and staples, splintered wood and missing stringers, results
in significant inefficiencies within the over-all distribution
system.
[0008] More and more companies are finding it preferable to employ
third-party pallet management services to control the costs and
logistics of using wooden pallets. For example, some fruit growers
require pallets on a seasonal basis. Wooden pallets may therefore
be rented for short or long terms from third parties. Third party
service companies offer nationwide access to pools of wooden
pallets, have responsibility for collecting and redeploying pallets
where they are needed, and keep the pallet pool at a relatively
high level of quality to move product through the distribution
channel. The pallet tracking and retrieval systems deployed by the
third party providers are more elaborate and efficient than other
segments within the wooden pallet market. For example, bar code
labels have been used to manage the efficiency of conventional
pallet assets. A direct line of sight is, however, required by the
scanner to read a bar card label. The performance of these systems
has been generally unreliable and costly to implement within a
wooden pallet environment.
[0009] Conventional Radio Frequency Identification (hereinafter
"RFID") systems have also been used but without success for a
number of reasons. For instance, there are too many makes and
models of 48 inch by 40 inch wooden pallet in the market. Also, a
standard protocol has not been advanced. Furthermore, pallet
handling procedures, material deterioration, product damage and
repair practices require a more robust RFID tag technology than is
currently available and wood is not a stable platform for the
attachment of many types of RFID tags. Additionally, radio
frequencies are absorbed by moisture in wood, which makes tag reads
unreliable. Standard harsh operating conditions within the wooden
pallet distribution system, such as thermal shock, sanitation,
flexure, vibration, compressive forces, and fork impacts, can cause
tag transponder coils to break and fail.
[0010] The velocity at which 48 inch by 40 inch wooden pallets
travel through the distribution system is far less than optimum
because a significant proportion of wooden pallets are not suitable
for transporting goods, damage free. Although 175 million pallets
are repaired each year, industry observers claim as many as 70% of
all wooden pallets have deteriorated from their original
specifications. Unacceptable wooden pallets have to be separated
from acceptable wooden pallets, which is time consuming, injurious
and wasteful. Accordingly, a far larger pool of wooden pallets is
maintained in operation than would otherwise be required under
optimum conditions. The traditional 48 inch by 40 inch wooden
pallet is therefore tremendously inefficient, costing industry
billions of dollars annually. Wooden pallets also have considerable
negative societal and environmental impacts because the recourses
used to purchase, repair and dispose wooden pallets could be more
effectively deployed in other less costly product technology
alternatives.
[0011] Accordingly, plastic pallets have been used to replace wood
pallets with some degree of success over the past several years.
Plastic pallets are known for their longevity and are generally
more durable, lighter weight, compatible with automated material
handling equipment, easily sanitized and 100 percent recyclable.
Conventional plastic pallets, however, suffer from one significant
disadvantage in that they cost considerably more than a comparable
wooden pallet. Thermoplastic materials constitute a significant
proportion of the total cost of a plastic pallet, and a given
amount of relatively expensive plastic material is required to
produce a pallet with a measure of load-bearing strength that is
comparable to wooden pallets.
[0012] As another example, U.S. Pat. No. 5,986,569 which issued to
Mish et al. proposes applying a pressure sensitive tape to the
backside of a tag carrier and affixing the carrier to an object.
Generally speaking, however, exterior attachment methodologies are
not sufficiently robust and durable. Tags affixed to the exterior
of the pallet can be damaged through wear and tear, sanitation,
forklift impacts, and the like. Also, U.S. Pat. No. 5,936,527 which
issued to Isaacman, et al., proposes a "cell" comprising a host
transceiver and several local hard lined interrogators that detect
local tags. In the Isaacman arrangement, several cells can be
networked, which allows any tagged object to be identified from any
PC within a multi-cell network.
[0013] It is significant that plastic pallet suppliers has been
unable to physically identify, locate and track, in real time,
comparatively expensive plastic pallets within networks of
distribution. It is one thing to lose a low cost wooden pallet, but
it is another to loose an expensive asset. Different technologies
have been proposed to attempt tracking of pallet assets within the
distribution system, but these proposals have been incomplete with
respect to system architectures, protocols and plastic pallet
design intent. Barcodes have been used, but these require a direct
line of sight and have therefore been difficult to implement. RFID
tags have been placed upon traditional molded pallets to locate and
track their positions within the distribution system, but this type
of pallet is so much more expensive than a comparable wooden pallet
that the cost justification for implementation is not
economical.
[0014] Moreover, it is known that conditions within the operating
environment affect the performance of the RFID system. Several U.S.
patents disclose protocols, circuitry architectures and other
enabling methods for ensuring the interrogator properly
communicates with one or more tags within an interrogation zone;
these include: U.S. Pat. No. 5,229,648 which issued to Shindley et
al.; U.S. Pat. No. 5,479,416 which issued to Snodgrass et al.; U.S.
Pat. No. 5,539,775 which issued to Tuttle et al.; U.S. Pa. No.
5,583,819 which issued to Roesner et al.; U.S. Pat. No. 5,818,348
which issued to Walezak et al.; U.S. Pat. No. 5,822,714 which
issued to Cato; U.S. Pat. No. 5,929,779 which issued to MacLellen
et al.; U.S. Pat. No. 5,942,987 which issued to Heinrich et al.;
U.S. Pat. No. 5,955,950 which issued to Gallagher et al.; U.S. Pat.
No. 5,963,144 which issued to Kruest and U.S. Pat. No. 5,986,570
which issued to Black et al. Still other proposals are offered to
overcome the antenna-to-antenna communication difficulties
conventionally experienced by tag carriers, such as pallets, as
they travel through interrogation fields or portals. The rapidly
changing angular geometry of a tag passing through a field or
portal results in a diminishing duration and strength of signal
transmission, which can produce unreliable tag reading results. The
following U.S. Patent Nos. propose solutions to this particular
problem: U.S. Pat. No. 5,661,457 which issued to Ghaffari et al.;
U.S. Pat. No. 5,708,423 which issued to Ghaffari et al.; U.S. Pat.
No. 5,686,928 which issued to Pritchett et al.; U.S. Pat. No.
5,995,898 which issued to Tuttle; and U.S. Pat. No. 5,999,091 which
issued to Wortham.
SUMMARY OF THE INVENTION
[0015] In accordance with the present invention there is provided a
system that provides electronic product data to a component of an
industrial control system. A component stores electronic product
data obtained from a Radio Frequency Identification (RFID) tag in a
structured format, the RFID tag is affixed to a product. An
interface provides the electronic product data to an industrial
controller, the interface utilizes a Programmable Logic Controller
(PLC) interface to read and write at least one of an input, an
output, a tag, a state, and a status parameter to the industrial
controller.
[0016] Further in accordance with the present invention there is
provided a system that manages the exchange of electronic product
data with an industrial controller. A RFID interface receives
electronic product data. A processing component parses the
electronic product data and groups related electronic product data.
An interface component provides the electronic product data to an
industrial controller, the interface component utilizes a PLC
interface to read and write at least one of an input, an output, a
tag, a state, and a status parameter to the industrial
controller.
[0017] Additionally the present invention is directed to A method
for conveying electronic product data to components in an
industrial control system. A subscription is received from an
entity within an industrial control system for electronic product
data. The electronic product data is obtained from an RFID product
tag through an RFID reader. The electronic data is formatted in a
structured form. The formatted electronic product data is conveyed
to the subscribing entity, the conveying utilizes a PLC interface
to read and write at least one of an input, an output, a tag, a
state, and a status parameter to the industrial controller.
[0018] Further the present invention is directed to a method for
distributing electronic product data to an industrial control
system. Electronic product data is received from one of an RFID
reader and a server. The electronic data is filtered to mitigate
duplicate data. The accepted electronic product data is processed
to a format in accordance with the industrial control system. The
formatted electronic product data is stored. The stored electronic
product data is conveyed to a component of the industrial control
system component, the conveying utilizes a PLC interface to read
and write at least one of an input, an output, a tag, a state, and
a status parameter to the industrial controller.
[0019] Further the present invention is directed to a thermoforming
apparatus that a system that facilitates electronic data
distribution to an industrial component. Electronic data is
obtained from one or more RFID readers or one or more RFID servers.
The electronic data is stored in a structured format. The stored
one or more data is conveyed to the industrial component, the
conveying utilizes a PLC interface to read and write at least one
of an input, an output, a tag, a state, and a status parameter to
the industrial controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view showing a preferred embodiment
of a thermoformed pallet having a radio frequency device of the
present invention.
[0021] FIG. 2 is a fragmentary perspective view showing a twin
sheet variation of the present invention pallet.
[0022] FIG. 3 is a perspective and fragmentary view showing a
second variation of the present invention pallet.
[0023] FIG. 4 is a perspective view showing the radio frequency
device employed in the present invention pallet.
[0024] FIGS. 5-7 are diagrammatic views showing the manufacturing
process employed with the present invention pallet.
[0025] FIG. 8 is diagrammatic perspective view showing the
orientation of one radio frequency device arrangement incorporated
into the present invention pallet.
[0026] FIG. 9 is a diagrammatic view showing the manufacturing
process employed with the present invention pallet.
[0027] FIGS. 10-12 are cross sectional views showing various radio
frequency device locations within the present invention pallet.
[0028] FIG. 13 is a diagrammatic view showing the interaction
between an interrogator and the radio frequency device employed
with the present invention pallet.
[0029] FIG. 14 is a top elevational view showing an exemplary radio
frequency device orientation employed with the present invention
pallet.
[0030] FIG. 15 is a diagrammatic view showing the interaction
between the interrogator and radio frequency device employed with
the present invention pallet.
[0031] FIG. 16 is an exploded perspective view showing an
interrogator incorporated into an alternate embodiment of the
present invention pallet.
[0032] FIG. 17 is a cross sectional view showing replacement of a
battery for the alternate embodiment of the present invention
pallet.
[0033] FIG. 18 is a flow chart showing another preferred embodiment
of the present invention pallet.
[0034] FIG. 19 is a diagrammatic view showing another preferred
embodiment manufacturing process employed with the present
invention pallet.
[0035] FIG. 20 is a perspective view showing the present invention
pallet of FIG. 19.
[0036] FIG. 21 is a fragmentary side elevation view showing the
present invention pallet of FIG. 20.
[0037] FIG. 22 is a cross-sectional view of a preferred embodiment
tank container of the present invention.
[0038] FIG. 23 is a diagrammatic view showing another preferred
embodiment tank container of the present invention.
[0039] FIG. 24 is an exploded perspective view showing an alternate
embodiment renewable power supply device employed in the present
invention apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Referring to FIGS. 1-3, the preferred embodiments of a
pallet apparatus 2 of the present invention employs a nesting
pallet 4 and a communications device, such as a radio frequency
identification device 16. Nesting pallet 4 has downwardly extending
pallet legs 6 which are receivable in pallet pockets 8 of an
adjacent pallet to provide a nesting configuration for consolidated
storage and transportation. Pallet 4 is made of a plurality of
polymeric plastic sheets thermoformed into a single article. Pallet
4 includes a top plastic sheet 10 and a bottom plastic sheet 12.
This arrangement is referred to as a twin sheet construction. In
one preferred embodiment, plastic sheet 14, shown in FIG. 3, is
sandwiched between sheets 10 and 12, in what is referred to as a
triple sheet construction. One advantage of a triple sheet
construction is that the same load bearing strength of a twin sheet
construction can be provided with a much lower measure of
relatively expensive plastic in a triple sheet construction.
Therefore, depending upon the criteria of the end-user, triple
sheet constructions can be used to provide either a lower cost or a
stronger pallet 4. The present invention pallet 4 can be made in
accordance with U.S. patent application Ser. No. 09/377,792,
entitled "Triple Sheet Thermoforming Apparatus, Methods and
Articles" which was filed on Aug. 20, 1999 by S. Muirhead; this is
incorporated by reference herein. In summary, this method of triple
sheet thermoforming provides the same measure of load bearing
strength with 25 percent to 50 percent less plastic material than
current state of the art twin sheet thermoformed pallets. However,
twin sheet thermoformed pallets characterized by U.S. Pat. No.
4,428,306 to Dresen et al., U.S. Pat. No. 5,638,760 to Jordan et
al., or U.S. Pat. No. 5,676,064 to Shuert, can be used to practice
certain aspects of the invention; these patents are incorporated by
reference herein. A triple sheet thermoformed pallet is preferred
because it provides a higher measure of strength for the given
measure of plastic used by a twin sheet pallet, and is therefore
more economically fulfilling the need for a low cost alternative to
wooden pallets.
[0041] The RFID system is minimally composed of three components
including an interrogator (reader or exciter), tag devises 16, and
a host computer. The tag is alerted by a radio frequency wave
transmitted by the interrogator to return a data message by
arrangement. The information stored in memory is thus transmitted
back to the interrogator. Information received by an interrogator
is used by a host computer to provide a reliable and a secure
architecture that meets predetermined performance requirements. In
passive RFID systems, the RF field generates voltage that is
rectified to power the tag. In active RFID systems, a battery is
the source of a tag's power supply. Both passive and active RFID
devises may be embedded within the structure of the preferred
plastic pallet.
[0042] Radio frequency identification tags and interrogators can be
made in accordance with the following U.S. Pat. No. 6,027,027
entitled "Luggage Tag Assembly" which issued to Smithgall on Feb.
22, 2000 and U.S. Pat. No. 6,013,949 entitled "Miniature Radio
Frequency Transceiver" which issued to Tuttle on Jan. 11, 2000.
Both of these patents are incorporated by reference herein.
[0043] RFID device 16 is encapsulated between the sheets forming
pallet 4. In general, thermoplastic resins are extruded through a
machine that produces a selective sheet or web of heat deformable
plastic. As the preformed sheet or web travels through the
extruder, one or more surfaces of the sheet receives one or more
RFID tags. This may be done automatically or manually such that the
tag is located on the plastic according to predetermined criteria
corresponding to a select molding position upon the thermoforming
tooling. Sheet thus tagged moves through a thermoforming machine
that molds said sheet into a finished pallet. The tag or tags are
sandwiched between the sheets of plastic forming the pallet at
predetermined locations. In this manner, the tag is embedded,
isolated, protected and contained in a fluid tight plastic barrier
that is resilient and long lasting and not externally, physically
visible. In order to ensure the RFID device is not damaged in the
thermoforming process of preference, a high temperature RFID devise
methodology, such as that described in U.S. Pat. No. 5,973,599
which issued to Nicholson et al., may be used; this patent is also
incorporated by reference herein. The location of the device within
the pallet is selected for system requirements. A plurality of
locations can be used by cross-referencing machine and extrusion
direction dimension references upon the plastic sheet with their
counter part locations upon the properly thermoformed article.
Thus, through such registration techniques, a consistent location
for positioning the tag upon the sheet relative to its selected
location in the finished part can be repeated with a high degree of
certainty. In more detail, molded-in structures of the plastic
pallet may be adapted to further protect the RFID device from
flexural and compressive forces that may other wise damage the
device.
[0044] The RFID devise 16 is part of a system in which data about
the pallet 2 is stored for retrieval according to system criteria.
The advantage of encapsulating RFID devise 16 within the structure
a pallet 4 is so that the devise 16 is protected from the harsh
environment that pallet 4 must operate within.
[0045] There are a number of methods that can be used to insert a
RFID devise 16 within thermoformed pallet 4. In one embodiment,
RFID devise 16 is a passive RFID tag 18. An example of such a
passive tag 18 is shown in FIG. 4. Tag 18 comprises an antenna coil
20, modulation circuitry 22 and micro-memory chip or integrated
circuit 24. Tag 18 is ultra thin, and in the order of 1 and 1/2
square inches. A plurality of tags 18 are normally placed upon a
polymer tape substrate by the tag manufacturer and delivered on
reels for integration into a manufacturing process.
[0046] A plastic sheet is heated to a deformable temperature before
it is molded by differential vacuum pressure over a mold.
Intervention is required to integrate the tag 18 into the present
thermoforming process in order to minimize stretching and heat
deformation of the PET substrate. As shown in FIGS. 4-6, the first
means of intervention includes depositing the coil 20 and circuitry
22 (composed of printable conductive ink) and the memory chip 24
upon a flexible film substrate 26. Substrate 26 is composed of a
plastic material that has a high heat deflection capability of
>600.degree. F., such as Rodgers Engineering's electrical grade
HT 12-1024 resin. After the tag 18 components are deposited onto
the substrate 26, a film substrate 28 of substantially the same
construction is laminated over substrate 26 with a suitable high
temperature resistant adhesive 30 there between to provide a double
layered substrate assembly 32. A first pressure sensitive, double
sided film 36a is then applied to substrate assembly 32 on the
substrate side. Substrate assembly 32 is subsequently sliced or
severed such that individual tags 18a are produced. The tags 18 are
separately and possibly sequentially deposited onto a paper or
plastic carrier 34 with a single sided, pressure sensitive adhesive
film 36b. Plastic carrier 34 is wound around a hub 38 to produce a
reel 40 that comprises a plurality of tags 18 that adhered to the
surface of a plastic sheet by way of first adhesive film 36a.
[0047] This arrangement produces a tag construction that is
resistant to deformation under the short-term and high heat
environment of the thermoforming process. Substrate 32 of tag 18
will not significantly stretch as the attached sheet 62 is deformed
over a three dimensional molding surface. Moments of shear at the
location of the tag 18 will also be deflected through movement of
the adhesive film 36a. Adhesive 30. will deflect compression upon
the memory chip by providing a compression buffer (thickness) equal
to the elevation of the memory chip 24. In this manner, the tag 18
is developed to sustain the rigors of thermoforming.
[0048] Another alternate variation of the communications device in
the structure of the pallet provides a power supply, an antenna, a
radio frequency transmitter, a radio frequency receiver, a digital
signal processor, a pallet information memory chip set, a pallet
identification reader card, and circuitry. The memory chip set
controls the function of the communicator and the identification
reader card identifies the communicator and pallet. The
communications device will thereby remotely communicate with an
external interrogator in a wireless manner, such as by cellular
telephone types of transmissions. This is used to instruct the
interrogator to then query tags on or in the pallet or container.
The interrogator also includes a power supply, an antenna, a radio
frequency transmitter, a radio frequency receiver, a data
processing micro-controller and circuitry.
[0049] Referring to FIG. 7, an X-Y gantry 42 is positioned along
the path traveled by the web 44 of plastic material produced by the
sheet extrusion machine (not shown). Gantry 42 cooperates with a
programmable logic controller (hereinafter "PLC") 46 that is
connected to a local area networked personal computer (hereinafter
"LAN PC") 48. Gantry 42 comprises linear high-speed indexer 50 that
travels horizontally back and forth according to instructions from
PLC 46. Indexer 50 further comprises a reel 40 (see FIG. 6)-to-reel
52 winder apparatus 54 with a vertical press 56. As the web 44
travels through the gantry 42, indexer 50 travels to a pre-defined
location 58, the winder apparatus 54 meters the reel 40 forward,
carrying tag 18 into vertical alignment with press 56. Press 56 is
instructed to travel vertically to stamp tag 18 onto the web 44.
Plastic web 44 travels the length of the extruder and is finally
sheared into a standardized sheet dimension at the end of the line
thereby defining sheet 62. Subsequently, the sheet and tag 18 are
transported to a thermoforming machine for processing.
[0050] Referring to FIG. 8, plastic web 44 is adapted in the
machine and extrusion directions to produce a plastic sheet that is
dimensioned to be thermoformed against four separate molding
application surfaces 64a, 64b, 64c and 64d, illustrated separately
by dashed line areas. In this manner, four pallets 4 are produced
simultaneously in the thermoforming operation. Multiple tags 18 are
located on sheet 62. On each of surfaces 64a and 64b, there are
three tags 18. There are also two tags 18 on surfaces 64c and 64d.
Thus, batches of pallets 4 can be custom made for different
end-uses. The PC 48 interfaces with PLC 46 to instruct indexer 50
to deposit tags 18 in a selective manner. In other embodiments of
the present invention, there may be multiple gantries 42 or
multiple indexers 50 on one gantry 42 for depositing a variety of
RFID tags 18a, 18b, 18c, 18d and 18e upon sheet 62. Alternatively,
host computer 80 may interface with LAN PC instructing further
systems (not shown) to apply a sequential array of tags 18a, 18b,
18c, 18d or 18e upon the carrier 34 (see FIG. 6) producing reel 40,
in the corresponding order to their deposition upon the sheet
62.
[0051] In the preferred order of arrangement shown in FIG. 9, sheet
62 is thermoformed against a female mold located upon the lower
platen of the thermoforming machine. In this manner, when sheet 62
is thermoformed, tags 18 will be encapsulated when molded sheet 68
is selectively fused to sheet 62 in the thermoforming process. This
creates a protective barrier around the each tag 18. It should be
appreciated, however, that other sheet forming sequences may be
utilized in a variety of thermoforming techniques to accomplish the
present method.
[0052] One of the tags 18, in this example tag 18a, interfaces with
a Manufacturing Management System (hereinafter "MMS") deployed
throughout the overall manufacturing infrastructure. Sheets 62, 68
and 70 (in the triple sheet method) are conveyed to a thermoforming
machine RF interrogator field 72, where a RFID tag interrogator 74
identifies and reads data stored on tags 18a. Tags 18a send
preprogrammed data packages back to interrogator 74a. Interrogator
74a interfaces with LAN PC 76 connected to thermoforming machine
PLC 78 interfacing through LAN to MMS host computer 80. PLC 78
instructs machine and ancillary equipment how to process the
plastic sheets 62, 68 and/or 70. PLC 76 next instructs tooling 77
how to process the plastic sheets 62, 68 and/or 70. If MMS criteria
are not met, the thermoforming process is disabled. If MMS criteria
are met, tag 18a traverses an interrogator field 82 and tag 18a
writes and locks final data into non-volatile tag 18a memory before
the pallet 4 exits said field to enter the supply chain. Other tags
18b, 18c, 18d and 18e do not interface with interrogator fields 72
and 82.
[0053] Referring now to FIG. 10, pallet 4 is adapted to enhance the
ability of devices 16 to survive long term pallet handling wear and
tear. In particular, the tines 82 of a forklift vehicle 131 are
used to move pallets 4 throughout the distribution network. When
tines 82 are introduced between pallet legs 6 in order to support
the weight of the pallet 4 for transportation, several potentially
damaging events may occur. For example, the tines 82 may impact the
sidewalls 84 of the Pallet 4 or the legs 6. Therefore, when systems
(new and pre-existing) criteria necessitates a relatively close
read range, and it is desirable to position the devices 16 in the
area of a side wall 84 or the outside feet 86, it would be
advantageous to affix devices 16, such as tags 18 on the lower
sheet of plastic 12 away from potential areas of tine 82 impacts.
Devices 16 can also be advantageously positioned on sheet 10 as may
be preferred in the embodiment used, with several acceptable
locations being shown. As tines 82 are introduced through pallet 4,
abrasion and shear may also occur along the path traveled by the
tines 82. Accordingly, locations containing devices 16 may be
reinforced to absorb and protect a device chamber 88 within which
the devices 16 reside. This is illustrated in FIG. 11. A variety of
potential chamber designs are possible in both twin and triple
sheet constructions. In twin sheet constructions, the preferred
methodology is to encapsulate each device 16 between two sheets of
plastic 10 and 12 in an arrangement that provides compressive,
flexural, shear and anti-abrasion strength in a zone 90 contiguous
to the chamber 88. A vertical side wall 92 of sheet 12
circumventing chamber 88 may incorporate vertical details 94 and/or
horizontal details 96, improving the strengthening criteria.
Chamber 88 is further strengthened by top sheet 10 being locally
recessed or lowered in side-to-side elevation so as to position the
chamber away from the load bearing surface of pallet 4 and in
particular the edges of packaging and objects supported
thereon.
[0054] In triple sheet constructions, other pallet strengthening
techniques can be used to increase the survivability of devices 16
within chamber 88. Sheets 62, 68 and 70 are formed to substantially
position chamber 88 between the top load-bearing surface 98 and the
bottom tine contacting surface 100 of pallet 4 so that the devices
16 are isolated from damaging events within the core of the pallet
4. This arrangement is illustrated in FIG. 12.
[0055] As understood in reference to FIG. 13, devices 16, and in
particular tag 18b, are transported through zone 102 proximate
interrogator 104. Interrogator 104 interfaces with a LAN PC 106
networked to a Warehouse Management System (hereinafter "WMS").
This creates an implementation criteria that is reliable and secure
for data retrieval and storage occurring while the pallet 4
transits through zone 102. When the read/write distance capability
of the interrogator 104 is limited and necessitates a predetermined
orientation of pallet 4, some inconvenience may occur because the
pallet 4 will have to be rotated 180.degree.. As this is
impractical within a smooth flowing WMS, two means of interventions
may be taken to prevent this undesired handling. A first means is
to apply color-coded polymeric strip 110 upon the plastic sheet 70
(see FIGS. 19 and 20) at the time of extrusion which corresponds to
the location of the devices 16. In this manner, the pallet may be
oriented by visual design for expediency. This will be discussed in
further detail hereinafter.
[0056] System interference may also occur if a nearby devises 16
travels outside the interrogation zone 102 but through the
interrogator's signal pattern 112. Similarly, as the pallet 4 is
traveling through the WMS, devise 16 may excite other interrogators
coming within reader range. These occurrences may lead to
unreliable data. In order to minimize these and other potential
problems, it is preferred to encapsulate devises 16 along a center
axis 114 of pallet 4. This is shown in FIG. 14, axis 114 may
progress from either the long or short side of a 48 inch by 40 inch
pallet 4. Devises 16 are positioned along an axis 114, which
resides in a zone 115 contiguous to the center leg 116 of the
pallet 4. In this manner, the tag 18 can be interrogated from
either the right or left hand side of the pallet 4.
[0057] Referring to FIG. 15, where a RFID system is being employed
within a new setting, it is advantageous to position elements of a
fixed field interrogator, such as a transit portal 117, upon, below
or well above the ground along the path transited by the pallet 4.
Accordingly, an over or an under bearing RF link is provided when
pallet 4 travels through the interrogator field 102b. This
arrangement also ensures that spaced apart metal tines 82 do not
deflect interrogator signals, thus causing unreliable reads. In the
preferred embodiment, elements of the interrogator that are
positioned for an over or under bearing read pattern include the
interrogator antenna assembly 118 and transmitter and receiver
modules 120 and 122, respectively, and an interrogator data
processing and control module 124, which is proximate LAN PC 126.
With this arrangement, improved read capability is integral to
criteria for implementation reliability and security.
[0058] It may also be understood in connection with FIG. 15, that
PC 126 may communicate with read result display(s) 127a positioned
proximate interrogation zone 102b in a fixed location visible to
the operator controlling the movement of the pallet, or wirelessly
to a display 127b on a console 129 of a motorized pallet
transporting vehicle 131. In this manner, the system is integrated
to facilitate economical movement of pallets 4 through
interrogation portal 117 and distribution network.
[0059] In the present invention, a pallet and corresponding load of
tagged objects, or stack of pallets, is positioned within the
interrogation zone by a manually operated motorized pallet
transporting vehicle. The interrogation field detects the vehicle
within the zone by a triggering devise. The interrogator
communicates with the tags in the zone, and upon completion of this
task, communicates with a visual message delivery devise that is
operative to instruct the driver to exit the interrogation field or
pass through the portal. An LED light or the equivalent can be
positioned on the drive console of the vehicle to inform the driver
to stop and proceed. A stop and go light arrangement can also be
positioned within the field of view of the driver to achieve the
desired communication. Alternatively, the host computer receiving
pallet information can interface with pallet transporting vehicle
by displaying on a console where the pallet is to be stored within
the warehouse.
[0060] Reference should now be made of FIG. 16. Another feature of
the present invention employs encapsulating interrogator
communications device 130 between the sheets forming the pallet 4.
Interrogator 130 could be adapted through system architecture to
take an inventory of the tags 18 or sub-set of tags 18 residing
upon the pallet 4. It should be appreciated that interrogator 130
is a substantially larger devise 16 than tag 18. It may therefore
be impractical to encapsulate the interrogator 130 within the
pallet 4 in the process manner outlined above. In order to insert
the interrogator 130 within the pallet 4, the following
methodologies would be preferred. In a twin sheet pallet
construction, interrogator 130 is delivered to a selected location
by means of a shuttle type delivery system that is adapted to move
from a position outside the form station where apparatus loads an
interrogator from a supply, to a position inside the form station,
where the apparatus unloads the interrogator; it then shuttles back
to load another interrogator, in between the time the first sheet
10 is thermoformed and when it is sequentially fused to
thermoformed second sheet 12. The shuttle type delivery system
could also be adapted to locate a plurality of devises 16, also
including tags 18, between the time the first sheet 10 is molded
and the second sheet 12 is fused to the first sheet 10 in a twin
sheet construction. A shuttle system of the type may alternately be
substituted with a robotic arm.
[0061] It will also be appreciated that interrogator 130 will draw
a considerable amount of power for operation. Interrogator 130 is
therefore active, with power supplied from a battery 132. From time
to time, interrogator battery 132 may be replaced according to a
maintenance schedule contained in data array of one of tags 18,
preferably tag 18a. As was also the case with tags 18, interrogator
130 will fail if delicate instruments 133, memory and integrated
circuit chips 133a or circuitry 135 printed on a circuit board 137
are damaged during the high temperature and compression events of
the thermoforming process. Intervention is thus required to insert
battery-powered devise(s) 16 between sheets of plastic.
[0062] Interrogator 130 is enclosed in a heat and compression
resistant thermoplastic housing 134. The housing base 134b has a
flange and thread section 135. Thread section 135 accepts a
thermoplastic seal and threaded plate 136. The plate 136 is
removable to replace or recharge battery 132. Tags 18 may also be
embedded in pallet 4 inside housing 134. Alternatively, tags 18 are
manufactured or deposited upon circuit board 137 of interrogator
130. As shown battery, 132 may be mounted to plate 136 adapted to
reconnect the battery as the plate is threaded to a closed
position. Spring terminals 138, concentrically arranged about an
axis corresponding to the rotational path of the terminals 139 on
the affixed battery 132, are developed to ensure robust connection
and enduring power supply. An EMI shield 141 is provided to prevent
tag reading interference; otherwise multiple pallets with goods on
each pallet stored on warehouse racking may demand the use of a
directional antenna 142. Housing flange 135 is larger in diameter
than the circuit board assembly. The circuit board assembly can be
removed for maintenance, upgrading and recycling of the pallet 4.
It is preferred that the housing 134 is recyclable with pallet when
emptied. Other arrangements enclosing the devises in protective
housings to withstand the rigors of thermoforming are also
practical.
[0063] In order for the pallet interrogator 130 to communicate with
a LAN PC, a Wireless Wide Area Communication System 140 is added.
System 140 can be a cellular communicator inter-operating in an
open standard environment. In the event FCC's E-911 mandate
precludes utilizing cellular communications in this application
(i.e. GPS), an alternative technology that can be used is wireless
PC communications. The circuitry of a RF based interface PC card
for a mobile PC devise could be deposited upon circuit board 137. A
local area Ethernet communicator interfaces the PC card circuitry
with a LAN PC, and through the LAN PC by the Internet to host
computer(s) 80. One or more circuit board antennas 142 may be slave
to several communications devises, as is battery 132.
[0064] In the triple sheet configuration of FIG. 17, housing 134 is
contained in chamber 88 formed between plastic sheets 12 and 14.
After first sheet 12 is thermoformed, a shuttle type delivery
system is used to deliver housing 134 to chamber 88 such that
flange 135 is selectively positioned upon first sheet 12.
Concurrently, sheet 14 is thermoformed. The shuttle is extracted
from the forming station, and interfacial fusion next occurs where
sheets 12 and 14 are compressed together in the thermoforming
operation. Housing 134 is enclosed between two sheets of plastic.
Third sheet 10 is thermoformed over a third molding surface and
subsequently brought into compressive contact with sheets 14 and
12. It is not necessary that sheet 10 fuse under compression with
sheet 14 at the location of interrogator chamber 88. Before (die
cut in mold) or after pallet 4 exits the thermoforming operation,
an orifice on sheet 12, adjacent threaded section 135, is removed
(by trimming) to later receive battery pack 132 affixed to plate
136. Alternatively, it may be advantageous to place housing 134
into a chamber formed by sheets 14 and 10. It may also be
advantageous to chill the plate so that when the plate expands
thermally, it produces a more robust closure.
[0065] The wireless interrogator is instructed to identify a
plurality or sub-set of the RFID tags associated with articles
supported upon the pallet. Thus, a pallet would be able to perform,
for example, its own inventory check by arrangement.
[0066] The present invention is further advantageous over
conventional systems, such as that disclosed in U.S. Pat. No.
5,936,527, since inserting a wireless active interrogator in a
plastic pallet of the present invention allows transportability and
can be instructed to perform an operation anywhere or at any
selected time within the wireless network. Examples of such a
wireless network includes digital telephony, satellite
communications, wireless Internet, microwave, cellular transmission
and the like. Among other alternative embodiments of this aspect,
is an optional renewable power supply devise 351 (see FIG. 16) that
rectifies voltage generated by antenna coils into stored energy in
a battery at the interrogator in the plastic pallet or container.
This affects battery size, replacement schedules, and other
problems associated with wireless active interrogators. This
renewable device generates energy, which recharges the associated
battery, spring or other power reservoir in response to external
agitational movement of the pallet during transit. The internal
mechanism for the renewable device can be made in accordance with
U.S. Pat. No. 4,500,213 entitled "Ultra-flat Self Winding Watch"
which issued to Grimm on Feb. 19, 1985, and is incorporated be
reference herein. The internal circuitry is shown in FIG. 24
wherein the capacitor acts as the power storage reservoir.
Renewable device 351, employs an oscillating weight 361, rotor 370,
top generating coil block 365, circuit block 367 with an integrated
circuit 370, bottom generating coil 369, capacitor/condenser 371
and battery/power source 373. Battery 373 is electrically connected
to the communications device, which includes an active tag 375, and
interrogator 377 and a communicator 379.
[0067] Moreover, the wireless active interrogators could also be
positioned within a molded structure forming part of the plastic
pallet. A battery supply information field could be part of the
manufacturing memory tag or third party pallet management memory
array as preventative maintenance schedule field.
[0068] Yet another advantage of the aspect of encapsulating a
plurality of RFID devises within the structure of a thermoformed
pallet is that the same pallet can be tracked through different
networks that interface according to differing substantially
proprietary protocols. There are several popular data encoding
methods, at least three data modulation standards and a handful of
proprietary anti-collision backscatter formats. It is unlikely that
in the future, one devise will be able to interface will all
deployed systems, because an open standard for interoperability has
not overcome issues with respect to proprietary technologies. There
is also a range of operating environments and computer operating
system platforms to interface with. A combination of devises within
one product that enables functionality at many locations with
pre-existing system infrastructures will help propel the plastic
pallet through the distribution system. Notwithstanding one tag
devise with several proprietary circuits could be coupled with one
or more memory chips, and one antenna coil.
[0069] According to yet another aspect of the invention, one or a
plurality of RFID devises may be provided within a single plastic
pallet. For example, one such tag may be dedicated to
manufacturing, material and recycle information storage. One tag
may be specifically adapted for pallet tracking within the
distribution system. The pallet may also host a third RFID devise
specified by third parties for specialized inventory tracking
activities within closed-loop or associated distribution networks.
A fourth tag may be developed to consolidate the data arrays of
several tags transported upon the pallet for more efficient data
compression and transfer. A fifth tag may be adapted for
interfacing with the RFID systems deployed by the trucking
industry. Accordingly, one or more RFID devises may be embedded
within one pallet to facilitate one or more operations according to
different implementation objectives that ultimately increase the
efficiency of plastic pallets.
[0070] According to this additional preferred aspect of the present
invention, one RFID devise maybe used during the manufacturing
process. A relatively simple, programmable passive RFID device that
provides a bi-directional interface for one-time programming and
multiple readings of the memory is used. The tag on the plastic
sheet is interrogated to instruct the PLC of the thermoforming
machine how the sheet is to be processed. In one such example, even
though the standard 48 inch by 40 inch wooden pallet is designed to
carry 2,800 pounds, the GMA claims approximately 30% of the unit
loads weigh less than 1,000 pounds, and 66% of unit loads weight
less than 2,000 pounds. Accordingly, the preferred thermoforming
method may be used to produce a select range of standard plastic
pallets, that are produced using different plastic formulations and
processing guidelines, to meet different distribution system needs.
The machine PLC may then be instructed to communicate to the
tooling to instruct the tooling how to process the successive
sheets. The thermoforming machine, production tooling and sheet
materials thus interface with each other to recognize, synchronize,
authenticate, implement and record manufacturing results to a
manufacturing biased host computer. The memory array of the
proposed devise is limited to read-only data transmission and is
disabled from accepting further programming or erasing instructions
once the pallet is made but before the tagged pallet enters the
pallet supply stream. The memory array of the manufacturing related
RFID devise will contain information pertaining to manufacture
date, serial number, load bearing capabilities, operating
temperatures, material composition, repair instructions, expiration
date, recycling requirements, ownership, ISO certificates and the
like. The data contained in the array could be tailored toward the
needs of a third party pallet rental/leasing company, which can
schedule and perform RFID and pallet maintenance.
[0071] This embodiment is explained in more detail as follows, with
reference to FIG. 18. An end user customer requests a custom made
final product by communicating his specifications manually to a
sales office or through a remote electrical communications
interface, such as the Internet. The control system computer will
use predetermined algorithms and look up tables to automatically
determine the optimum manufacturing criteria for these customer
specifications. The determined manufacturing criteria is
subsequently communicated to the tag manufacturing plant's local
host computer.
[0072] The tags are sequentially deposited upon a roll at which
point the tags receive selective data information which is
pre-programmed or stored in the memory of each tag. The pre-formed
sheets, containing the RFID tag, are subsequently conveyed to the
thermoforming plant or machinery for processing into end products,
shown in the figure as product A and product B.
[0073] The RFID tag on the sheet traverse and travel through the
interrogation filed prior to entry of the sheet into the
thermoforming machine. Data previously stored and programmed into
the RFID tag memory is thereby communicated to the thermoforming
machine PLC attached to the interrogator. The PLC thereby analyses
the received data and adjusts the manufacturing operation and
machinery as predetermined for the specific data criteria
analyzed.
[0074] For example, fire retardant fillers in the plastic sheet
require a longer period of time for heating in the ovens. Thus,
data regarding the presence of fire retardant materials, which has
been previously programmed or stored in the RFID tag memory,
instructs the PLC of its presence and the PLC then controls the
machinery to provide increased heat in the ovens for the specific
sheet about to enter the ovens. The next sheet to be processed many
not have a fire retardant filler and thus the PLC will accordingly
vary the machinery and processing operation to reduce the oven heat
applied to that subsequent sheet to be processed. In another
example, an end product may be desired to have a metal frame
inserted for increased load bearing strength. When the interrogator
receives this information from the RFID tag attached to a sheet to
be processed, the PLC operating the processing machinery will then
instruct an auxiliary input A machine to insert a metal frame
between a pair of sheets being processed. This can be done by a
robotic arm or through other automation. The process is completed
according to the preprogrammed manufacturing instructions in the
machinery PLC, as altered or varied by data stored in the RFID tag
for each sheet being processed. After completion, the PLC
communicates the record of completion to a network computer for
billing purposes and other statistical process control
information.
[0075] Still according to this aspect of the present invention, one
or more RFID devises can be used to identify, locate and track a
pallet within the distribution network throughout the pallet's life
cycle. In the manner, computer based tools can be utilized to
increase the velocity of the pallet through the system. In other
words, the pallets are managed as an asset rather than an expense.
The pallet is tracked using a more complex programmable RFID device
that provides a variety of operating modes (single tag/multiple tag
environments), including multiple write and read (EEPROM)
capabilities. Tagged pallets traverse interrogation fields
distributed throughout the distribution network to record the
pallet's progress through the distribution system. The RFID devises
include anti-collision modulation options to resolve backscatter
when multiple tags are in the same interrogation fields. Automatic
pallet material handling equipment is upgraded to accommodate
readers and communicators. Supply chain management and control of
the movement of pallets through the distribution system are
facilitated with real-time data input from the integrated RFID
system. Host, interrogator and tag interface according to various
implementation criteria, such as last scan time & date,
movement order number field, "from" field, "to" field, shipper
field, pallet rental release. field, and pallet return
instructions. RFID technology provides a two-way flow of
information between the pallet and the system server to help propel
the pallet through the distribution system. The RFID devise may
also carry its own electronic manifest. A more efficient use of
plastic pallets will reduce the total number of pallets required by
the over all distribution system.
[0076] According to a further feature of the invention, each RFID
devise that may be contained in the pallet may be developed to
operate on different radio frequencies (13.56 megahertz to 2.45
gigahertz) in order to optimize system performance and minimize the
cost of interrogators and tags. Each devise may use a different
coding waveform algorithm to reduce data recovery errors, bandwidth
problems, synchronization limitations and other system design and
cost considerations. For example, the pallet manufacturer does not
need interrogation systems interfacing with the tracking systems,
and versa visa. Thus, a less elaborate and costly RFID system is
needed by the thermoforming manufacturer to deploy RFID systems.
Similar tag devise transmissions may be echeloned according to
prescribed system criteria or other pallet management tools or
model algorithms.
[0077] As Faraday's law and Lenz's law are well known, it is also
understood that the parallel orientation, and distance between the
reader and tag antenna coils in respect of each other are important
for the successful operation of passive RFID devises in particular.
Read range is lower in higher frequency passive RFID devises.
Furthermore, it is understood that induction is maximized when the
antenna coils are perpendicular to the direction of the radio
frequency signal. Therefore, another feature of the present
invention provides for encapsulation of RFID devises within the
structure of the plastic pallet. In one embodiment, an interrogator
is contained in a vertical freestanding structure off to the side
of the path traveled by the RFID devise. Accordingly, the antenna
coils located in the interrogator and pallet are vertically
oriented in approximate parallel condition to facilitate a proper
signal transmission. In another embodiment, an interrogator is
placed upon or under ground along the path traveled by the pallet,
or alternatively suspended from above. In such an arrangement, it
is advantageous to orient the respective antenna coils
substantially horizontal in an approximate parallel condition to
facilitate induction. These later arrangements would be difficult
to duplicate and implement with wooden pallets because water
absorbed by the wood would impede or reflect the RF signal away
from the tag antenna.
[0078] A further preferred method of attaching RFID tags to
polymeric sheets is as follows, with reference to FIG. 19. A
polyethylene or polypropylene sheet 501 is created by an extruder
503 and a pair of opposed rolls 505. The continuously created sheet
is then fed through an indexer 507 at which point RFID tags 509 are
fed from tag rolls 511 which are deposited in a spaced fashion upon
an upper surface of sheet 501. A narrow roll of polyethylene or
polypropylene film 513 is simultaneously unwound from a film roll
517 and then compressed by a spring biased application roller 519
upon sheet 501 and covering each tag 509. The film is thermally
bonded to sheet 501 by compression of heated spring biased
application roller 519. The continuous sheet 501 is subsequently
sheared or cut into separate preformed sheets 521 by a shearing
machine 523.
[0079] It is alternately envisioned that the film is colored so
that it can be used to indicate tag location inside of a pallet for
correct orientation to provide accurate readings as previously
disclosed. For example, a plurality of colored films may be applied
to denote RFID tag implementation criteria. For example, FIGS. 20
and 21 show a four-up sheet wherein one operation yields four
formed parts; in other words, four pre-formed sheets, with
respective RFID tags, are not severed until after thermoforming.
Film 513 is shown in two distinct and parallel, elongated locations
covering RFID tags 509 upon the four-up sheet 521. Film 513 further
protects the underlying tags 509 as the leading edge 531 of a
subsequently severed sheet is angularly moved along a lower sheet
521 during stacking.
[0080] Another preferred embodiment application of the
thermoforming and communications device technology is shown in FIG.
22. In this embodiment, a gasoline fuel tank 601, such as those
used with an automobile, motorcycle, all-terrain vehicle, airplane,
boat or other motorized vehicle, is made using twin or triple sheet
thermoforming. Tank 601 is made of three, three-dimensionally
formed sheets of plastic, 603, 605 and 607, respectively, which are
all joined together during processing. A bottom hollow section 609
operably contains a liquid, such as gasoline fuel. A top hollow
section 611 contains fuel filler, filter, and other standard
devices 613 necessary for the operation of tank 601.
[0081] A communications device 621 is attached to an inside surface
of sheet 607 within top hollow section 611 prior to thermoforming,
as was previously disclosed herein with the pallet manufacturing.
As the fuel is removed for engine combustion, environmentally
hazardous gases are left to fill the space unoccupied by the fuel.
Top hollow section 611 acts as a reservoir that contains the
harmful gases that would otherwise escape through the devices 613
into the environment. The devices 613 can also recirculate the gas
back into the lower hollow sections 609, in a conventional manner.
An instrument section of communications device 621 is operable to
inspect and monitor the barrier performance of top hollow section
611 to ensure compliance with governmental regulations. When the
vehicle is inspected, the data generated and stored by the
instrument of device 621 is then conveyed through radio frequency
communications to an external monitoring device operated by the
governmental regulating authority for inspection purposes. The
instrument section of device 621 can be battery activated in an
active manner to provide regular intervals of inspection, can be
passive to receive power when externally interrogated, or can be
triggered one time when a predetermined threshold is met.
[0082] A further preferred application of the present invention is
shown in FIG. 23. A bulk container 701 operably carries a hazardous
material therein. For example, a two-part polyurethane container
system is made from three sheets 703, 705 and 707 which are
thermoformed and joined as previously disclosed herein to provide
container 701 with two reservoirs 709 and 711. Flange plates 713
and 715, having threads, are formed onto container 701 to receive
metering pump elements (not shown). These flange plates are made in
accordance with those disclosed for battery replacement in the
pallets. Pockets or receptacles 717 are created between adjacent
internal sheets 703 and 705 at an overlapping margin to receive
RFID tag devices. The RFID tags perform a range of functions which
include recording of chemical formulas of material contained within
reservoirs 709 and 711, storage of safety data for storing, clean
up information, worker injury information (such as that
traditionally contained on a material safety data sheet),
temperatures, thermal shock, and for disposal instructions. This
data can later be interrogated by and external interrogator or the
like.
[0083] While the preferred embodiment of the thermoformed pallet
having a radio frequency device has been disclosed, it should be
appreciated that other variations may be employed. For example,
with a shuttle type delivery system and methodology, the gantry and
laminator apparatus are not required. There are several other
methodologies that may be used to practice the useful purposes of
embedding sophisticated communications and other technological
devices within the structure of a plastic pallet 2. Furthermore,
analog or solid state circuitry can be employed instead of the
microprocessors, integrated circuits and computers disclosed. There
are a number of different reinforcing structures that can be molded
into two or more sheets of plastic to reinforce the area around the
devices 16. It is not necessary to form a complete chamber in
plastic, so long as device 16 remains in the areas developed to
protect the device from thermoforming shock, and operating wear and
tear. It is also understood that access to the devices may be from
the top or bottom in the wide variety of pallets contemplated in
the present methodology. Furthermore, the RFID tags can also be
attached to other heat and pressure formable sheets, such as
cardboard, fiberglass, or the like, prior to three dimensional
forming of the sheets. Additionally, the RFID tags and other
electrical communications devices can be employed to monitor food
conditions within a food container. While various materials have
been disclosed, it should be appreciated that other materials can
be employed. It is intended by the following claims to cover these
and any other departures from the disclosed embodiments which fall
within the true spirit of this invention.
* * * * *