Methods and systems for in-line RFID transponder assembly
Methods and apparatus for manufacturing corrugated paperboard are provided. The apparatus includes a linerboard feed device configured to supply a quantity of linerboard including a plurality of antennae coupled to a first planar surface of the linerboard, an optical sensor configured to locate a connection area of the plurality of antennae, and an attach mechanism configured to couple a radio frequency identification circuit to the connection area.
1 . An apparatus for manufacturing corrugated paperboard, said apparatus comprising:
a linerboard feed device configured to supply a quantity of linerboard including a plurality of antennae coupled to a first planar surface of the linerboard;
an optical sensor configured to locate a connection area of the plurality of antennae; and
an attach mechanism configured to couple a radio frequency identification circuit to the connection area.
2 . An apparatus in accordance with claim 1 further comprising:
a corrugator configured to corrugate a quantity of corrugating material stock into a corrugated medium; and
a double facer configured to join the corrugated medium to the linerboard on a side of the linerboard opposite the first planar surface to form a corrugated structure.
3 . An apparatus in accordance with claim 1 further comprising a printing press configured to couple the plurality of antennae to the linerboard using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process.
4 . A corrugate machine for manufacturing radio frequency identification enabled corrugated paperboard comprising:
a press configured to couple a plurality of antennae to a first planar surface of supply of linerboard;
a corrugator configured to corrugate a quantity of corrugating material stock into a corrugated medium;
a double facer configured to join the corrugated medium to the linerboard on a side of the linerboard opposite the first planar surface to form a corrugated structure;
an optical sensor configured to locate a connection area of the plurality of antennae; and
an attach mechanism configured to couple a radio frequency identification circuit to the connection area.
5 . A corrugate machine in accordance with claim 4 wherein the press is configured to print the plurality of antennae using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process;
6 . A corrugate machine in accordance with claim 4 wherein the press is configured to print the plurality of antennae using a conductive ink comprising at least one of copper, aluminum, silver, and organic conducting polymers.
7 . A corrugate machine in accordance with claim 4 wherein the press is configured to print the plurality of antennae using at least one of a plurality of layers of conductive ink, and a plurality of conductive ink layers and dielectric layers.
8 . A corrugate machine in accordance with claim 4 wherein the attach mechanism is located downstream from the double facer.
9 . A method of forming a corrugated panel comprising:
providing a plurality of antennae on a quantity of linerboard, the antennae printed using a conductive ink;
optically locating an antenna connection area; and
coupling a radio frequency identification circuit to the antenna connection area such that radio frequency energy received by the antenna is transmitted to the radio frequency identification circuit.
10 . A method in accordance with claim 9 wherein providing a plurality of antennae comprises printing the plurality of antennae using a conductive ink.
11 . A method in accordance with claim 10 wherein printing the plurality of antennae using a conductive ink comprises printing the plurality of antennae using a conductive ink that includes at least one of copper, aluminum, silver, and organic conducting polymers.
12 . A method in accordance with claim 10 wherein printing the plurality of antennae using a conductive ink comprises printing the plurality of antennae using at least one of a lithographic process, a flexographic process, a rotogravure process, a rotary screen print process, a drop-on-demand ink jet process, a continuous ink jet process, a spray process, a pad printing process, a pressure release substrate process, and a thermal transfer process.
13 . A method in accordance with claim 10 wherein printing the plurality of antennae using a conductive ink comprises printing the plurality of antennae using a plurality of layers of conductive ink.
14 . A method in accordance with claim 10 wherein printing the plurality of antennae using a conductive ink comprises printing the plurality of antennae using a plurality of dielectric layers.
15 . A method in accordance with claim 10 further comprising curing the conductive ink in a drying section of a corrugator.
16 . A method in accordance with claim 9 wherein providing a plurality of antennae comprises pre-printing the plurality of antennae on the linerboard using an off-line print process.
17 . A method in accordance with claim 9 wherein providing a plurality of antennae comprises providing the plurality of antennae upstream of a corrugator.
18 . A method in accordance with claim 9 wherein providing a plurality of antennae comprises applying a heat resistant overprint varnish (OPV) over at least a portion of the antenna such that the connection area is not covered by the OPV.
19 . A method in accordance with claim 9 wherein providing a plurality of antennae on a quantity of linerboard comprises providing a plurality of antennae on a side of the linerboard that is an external surface of the corrugated panel.
20 . A method in accordance with claim 9 wherein coupling a radio frequency identification circuit to the antenna connection area comprises coupling a radio frequency identification circuit to the antenna connection area downstream from a double facer.
21 . A method in accordance with claim 9 wherein coupling a radio frequency identification circuit to the antenna connection area comprises coupling the radio frequency identification circuit directly to a respective antenna connection area.
22 . A method in accordance with claim 9 wherein coupling a radio frequency identification circuit to the antenna connection area comprises coupling the radio frequency identification circuit to the antenna connection area using a strap.