DESC:TECHNICAL FIELD

The present disclosure generally relates to the field of manufacturing. Particularly but not exclusively, the present disclosure relates to manufacturing of a Radio Frequency Identification (RFID) tag. Further embodiments of the present disclosure discloses a system for joining a coil and an IC chip during manufacturing of the RFID tag.

BACKGROUND OF THE DISCLOSURE

RFID system enables radio communications to be carried out between RFID tags and an RFID reader-writer. Each of the RFID tags may be equipped with an IC chip and an antenna. The RFID tag works by transmitting and receiving information via the antenna and the IC chip also sometimes called a microchip. The IC chip embedded on an RFID reader may be fed or written with the information that is required by the user. RFID tags may include active-type tags each of which has a battery therein and runs from power stored in the battery. RFID tags may also be passive-type tags, each of which receives electric power through electromagnetic induction and runs from this electric power. Active-type tags have merits, such as a long communication range and communicative stability as compared with the passive-type tags, as they include a battery. However, active-type tags also have demerits, such as complication in their structure, enlargement of their size, and high cost.

Given the demerits of active-type tags and with the advancements in technology, downsizing and migration to higher performance of IC chips used for passive-type in semiconductor technologies can be seen. In the case of a passive-type tag of electromagnetic induction type which is applied to an RFID tag, voltage may be induced in the RFID tag due to electromagnetic induction between a transmission antenna coil of a reader-writer and an antenna coil of the RFID tag. This voltage starts the IC chip of the tag, so that communications may be carried out between them within the induction field caused by an RFID reader-writer. When a passive RFID tag is scanned by a reader, the reader transmits energy to the tag which powers it for the chip and antenna to relay information back to the reader. The reader then transmits this information back to an RFID computer program for interpretation.

RFID tags find a wide range of applications across various fields of technology. Its applications include but not limited to tracking of living subjects, tracking consumer products. RFID tags may also be used for tracking vehicles, airline passengers, Alzheimer's patients, pets etc. Thus, there is a huge demand for RFID tags.

In order to meet the growing demands of the market for RFID, efficiency has to be increased without reducing the reliability of the product. First step of manufacturing the RFID is to provide the connectivity between the terminals of the Integrated Circuit (IC) chip through pre-defined length of a conducting coil. Conventionally, the connection between the chip and the coil was done using soldering/welding process, which involves use of skilled labor. Further, for accurate connectivity between the IC chip and coil, alignment between the two is critical. Such construction included manual handling of coil as well as aligning the IC chip for manufacturing. This process may lead to manual errors and incorrect alignment of the RFID tag. Moreover, soldering/welding process require manual intervention in each stage such as aligning of leads of the coil, ensuring contact of the leads with the IC chip, and trimming of leads after joining. Also, the trimming of the leads manually after joining may induce stress on the soldered joint, which may result in failure of the joint.

The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the conventional arts.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by an assembly, method and an apparatus as claimed and additional advantages are provided through the provision of apparatus as claimed in the present disclosure. Additional features and advantages are realized through the aspects and techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In an exemplary embodiment of the present disclosure, a system for manufacturing a radio frequency identification (RFID) tag is disclosed. The system comprises a fixture assembly including a base plate for supporting an integrated circuit chip and a coil. The system includes a tensioner unit which is fixed to the base plate. The tensioner unit is positioned such that, leads of the coil is received between a pair of contact pads, and is configured to displace between a first position and a second position to maintain contact of the leads of the coil with the conductive pads of the IC chip for joining. Further, a cutter unit is fixed to the base plate adjacent to the tensioner unit, and the cutter unit is configured to displace and cut the extending portion of leads of the coil after joining.

In an embodiment, the base plate is configured with a first provision to receive the IC chip and a second provision to receive the coil.

In an embodiment, the tensioner unit comprises at least one first actuator connected to each of the pair of contact pads. The at least one first actuator is configured to displace the pair of contact plates relative to each other between an open position and a gripping position.

In an embodiment, tensioner unit comprises at least one second actuator connected to a base position of the at pair of contact pads. The at least one second actuator is configured to displace the pair of contact pads between the first position and the second position.

In an embodiment, the cutter unit comprises of at least one blade connected to the at least one third actuator to trim the extending portion of leads of the coil after joining.

In an embodiment, the at least one first actuator, the at least one second actuator and the at least one third actuator are one of pneumatic and hydraulic actuators.

In another exemplary embodiment of the present disclosure a method for manufacturing a radio frequency identification (RFID) tag is disclosed. The method includes displacing a pair of contact pads of a tensioner unit from a first position to a second position to maintain contact of the leads of a coil with a conductive pads of an IC chip, wherein the leads of the coil is received between the pair of contact pads for joining. The method further includes, cutting an extending portion of leads of the coil after joining by a cutter unit, wherein the cutter unit is fixed to the base plate adjacent to the tensioner unit.

In an embodiment, the tensioner unit aids in stiffening the leads of the coil on the IC chip to effectively join the IC chip and the coil.

In an embodiment, the joining operation is one of heat staking, welding, soldering and the like.

In an embodiment, the at least one first actuator, the at least one second actuator and the at least one third actuator are configured to actuate in a sequential order to complete the stiffening and cutting operations.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

FIG.1 illustrates exploded view of a system comprising a fixture assembly for manufacturing of an RFID tag, according to an embodiment of the present disclosure.

FIG.2 illustrates perspective view of a base plate of the fixture assembly for placing the IC chip and the coil, according to an embodiment of the present disclosure.

FIG.3 illustrates perspective view of a tensioner unit of the system of FIG. 1 with contact pads, according to an embodiment of the present disclosure.

FIG.4 illustrates perspective view of a cutter unit of the system of FIG.1 with blades for trimming the coil, according to an embodiment of the present disclosure.

FIG.5 illustrates perspective view of the coil and the IC chip post manufacturing by the system depicted in FIG. 1.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE DISCLOSURE

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that, the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other mechanism for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that an assembly, device or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

Embodiments of the present disclosure discloses a system for manufacturing a RFID tag. The system comprises a fixture assembly for aligning and joining a coil and an Integrated circuit (IC) chip for manufacturing a Radio Frequency Identification [RFID] tag, herein referred to as RFID. During the manufacture of RFID tag, the IC chip and the coil are major parts wherein, it is required for the coil to be aligned accurately with conductive pads present on the IC chip. Once the aligning of the coil and the IC chip is complete, the coil is then joined with the conductive pads of the IC chip. Conventionally, manual labor and manual soldering was used which may not be feasible and this could not be carried over to automation and hence the present disclosure discloses welding, particularly heat staking for joining the coil and the IC chip. The fixture assembly uses precise movements of its components in order to accurately join the coil with the IC chip during manufacturing of the RFID tag. Further, the fixture assembly may comprise of provisions for positioning the IC chip and the coil. In an embodiment, the fixture assembly may consist of one or more modules to adjust and align the coil with the IC chip.

Accordingly, after aligning of the coil on the IC chip, the system comprises of a fixture assembly comprising a tensioner unit configured to provide tension to ends of the coil. In an embodiment, once the ends of the coil are tensioned, the coil may be subject to joining process to join with the IC chip. While the coil and the IC chip are subject to joining, the system is also configured with a cutter unit to trim the excess coil. This way, the coil may be accurately trimmed to the required length and joined with the IC chip during manufacturing of the RFID circuit.
Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to Figs 1 to 5.

FIG.1 is an exemplary embodiment of the present disclosure which illustrates exploded view of a system having a fixture assembly (100) for welding a coil (103) and an Integrated Circuit (IC) chip (102) [shown in FIG. 5] during manufacturing of Radio Frequency Identification (RFID) tag. The coil (103) is received by a portion of a base plate (101) and is configured to be aligned on the conductive pads (not shown in figure) of the IC chip (102). The coil (103) which is aligned with the IC chip (102) is then subjected to a joining process to form an antenna of the RFID tag, which enables the coil (103) to transmit and receive signals from the IC chip (102). Thus, the present disclosure aims to provide an automated solution for aligning and joining by using the fixture assembly (100) of the present disclosure.

The system (100) used for welding the coil (103) and IC chip (102) broadly comprises two modules which may be operated sequentially in order to aid in joining the coil (103) and the IC chip (102). The system includes a fixture assembly (100) which comprises of the base plate (101) which supports all the components of the fixture assembly (100) during manufacturing of the RFID tag. Since, the base plate (101) is required to bear heavy loads, it may be made of a metallic material or any other material which serves the purpose. Further, the base plate (101) is also configured to receive the coil (103) and the IC chip (102) from a source such as an inventory and then positioning the same within the base plate (101). The fixture assembly may be configured to align the coil, IC chip and hold the same in place.

FIG.2 illustrates, a portion of the base plate (101) of the fixture assembly (100). This portion of the base plate (101) may comprise of provisions for placing the coil (103) and the IC chip (102). In an embodiment, there may be a first provision (104) configured to receive the IC chip (102) and a second provision (105) configured to receive the coil (103). In an embodiment, the second provision (105) may be substantially circular in shape, however it may be of other shapes as well as per the design of the coil (103) and the same is not to be construed as a limitation to the present disclosure. In an embodiment, a robotic arm or a robot may be configured to place the IC chip (102) in the first provision (104) and place the coil (103) within the second provision (105) respectively. The robotic arm or robot may be a part of a placing unit (not shown in figure) which is configured to place the IC chip (102) and the coil (103) in the fixture assembly (100). The system (200) may be configured with a control unit (not shown in figure) configured to operate the actuators in the fixture assembly. Further, the control unit is also configured to detect any errors in the operation.

In an embodiment, the fixture assembly (100) may include one or more modules (not shown in figures) to align the coil (103) with the IC chip (102). Aligning the coil (103) with the IC chip (102) may include aligning the IC chip (102) and arresting the vertical movement of the coil (103). Further steps include, aligning the ends of the coil (103) and then clamping the ends of the coil (103). The control unit may be configured to control the operations carried out by the one or more modules based on requirement.

Referring now to FIG.3, which illustrates perspective view of a tensioner unit (106) of the system. The tensioner unit (106) may be configured to provide tension to ends of the coil (103). The tensioner unit (106) may be fixed to the base plate (101) of the fixture assembly (100). The tensioner unit (106) may comprise at least one contact pad (107) on either side of the fixture assembly (100). The at least one contact pad (107) is operated by at least one first actuator (110). In an embodiment, there may be at least two contact pads (107) provided on either sides of the fixture assembly (100) and are configured to move towards each other to tension the leads of the coil (103) in between the at least two contact pads (107). The at least one first actuator (110) may be configured to displace the pair of contact pads (107) relative to each other between an open position and a gripping position. In the open position, the leads of the coil (103) are placed within the gap created in-between the at least two contact pads (107). The leads of the coil (103) are then gripped by the contact pads (107) when the at least one first actuator (110) is actuated, wherein upon actuation the contact pads move relative to each other to the gripping position. In an embodiment, the at least one first actuator (110) is used to actuate the at least one contact pads (107) that may be pneumatic actuators. In an embodiment, the contact pads (107) may be in the form of a square shaped geometry and may be made of a polymeric material. Further, the contact pads (107) may grip the leads of the coil (103) and move downwardly through a pre-determined distance from a first position (FP) to a second position (SP) to maintain contact between the leads of the coil (103) and the conductive pads of the IC chip (102). The downward movement of the contact pads (107) may be achieved by using at least one second actuator [not shown in figures]. The downward movement of the contact pads (107) applies tension to the leads of the coil (103) and maintains contact pressure between the coil (103) and the IC chip (102). The tensioner unit (106) may be necessary to firmly hold the coil (103) in its place during further operation of the fixture assembly (100). The alignment and tensioning of the coil (102) with respect to the IC chip (102) facilitates precise joining of the coil (103) with the IC chip (102). The joining may be carried out at various locations where the coil (103) comes in contact with the conductive pads of the IC chip (102). As an example, the joining may be carried out at three different spots on the IC chip (102) based on the requirement. In one embodiment, the process used to join the coil (103) with the IC chip (102) may be heat staking process.

Moving on to FIG.4, depicts a perspective view of a cutter unit (108) of the system. As the leads of the coil (103) are subjected to tension through the tensioner unit (106), the coil (103) is may be firmly held on conductive pads of the IC chip (102). The coil (103) and the IC chip (102) may be joined through welding or a heat staking process at one or more weld spots on the IC chip (102). Hence, after the joining process is completed the excessive leads of the coil (103) are to be trimmed. In an embodiment, the cutter unit (108) may consist of plurality of blades (109) to trim the excess coil upon completion of the welding operation. The plurality of blades (109) may be actuated by at least one third actuator (111) connectable to the cutter unit (108). The cutter unit (108) is positioned adjacent to the tensioner unit (106) in the fixture assembly (100). Trimming of the excess coil (103) may be carried out simultaneously with the joining operation. For instance, once the first spot of the left lead of the coil (103) is joined, corresponding side of the coil (103) may trimmed through the plurality of blades (109) and once the second and third spots are joined, the corresponding lead of the excess coil (103) may be trimmed. In an embodiment, the blades (109) may be provided on either sides of the fixture assembly (100) and may be more than one in number.

FIG. 5 illustrates the aligned IC chip (102) and the coil (103). In an embodiment, the IC chip (102) and the coil (103) are aligned, such that the leads of the coil (103) passes over the conductive pads (118) of the IC chip (102). The point at which the leads of the coil (103) comes in contact with the conductive pads (118) of the IC chip is subjected to joining process to fuse the coil (103) with the IC chip (102).

In an embodiment, the joining of the IC chip (102) with the coil (103) may be achieved using process such as but not limiting to welding, heat staking, soldering, and the like.

In an embodiment, the actuators may be one of pneumatic and hydraulic actuators.

In an embodiment, the coil (103) is an antenna to transmit signals from the IC chip (102) of the RFID tag to a reader-writer.

In an embodiment, the base plate (101) may be manufactured using metals like but not limited to iron, aluminium, steel and the like.

In an embodiment, the tensioner unit (106) and the cutter unit (108) are fixed to the base plate (101) using various fastening methods.

In an embodiment, the shape of the second provision to house the coil (103) may be of circular shape, square shape, rectangular shape, triangular shape, or any other geometrical shape based on requirements.

In an embodiment, the fixture assembly (100), the tensioner unit (106) and the cutter unit (108) may be automated by associating it to a computer or a smart device, wherein the computer or smart device controls the actuators to perform the required operations.

In an embodiment, the at least one first actuator (110), the second actuator and the at least one third actuator (111) may be configured to actuate in a sequential order to complete the tensioning and trimming process as per requirement.

Equivalents:

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base plate or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Referral Numerals:

Reference Number Description
100 Fixture assembly
200 System
101 Base plate
102 IC chip
103 Coil
104 First provision
105 Second provision
106 Tensioner unit
107 Contact pads
108 Cutter unit
109 Blades
110 At least one first actuator
111 At least one third actuator
,CLAIMS:We Claim:

1. A system (200) for manufacturing a radio frequency identification (RFID) tag, the system (200) comprising:
a fixture assembly (100), comprising:
a base plate (101) for supporting an integrated circuit (IC) chip (102) and a coil (103);
a tensioner unit (106) fixed to the base plate (101), wherein the tensioner unit (106) is positioned such that, leads of the coil (103) is received between a pair of contact pads (107), and is configured to displace between a first position (FP) and a second position (SP) to maintain contact of the leads with the conductive pads of the IC chip (102) for joining;
a cutter unit (108) fixed to the base plate (101) adjacent to the tensioner unit (106), wherein the cutter unit (108) is configured to displace and cut an extending portion of leads of the coil (103) after joining.

2. The system (200) as claimed in claim 1, wherein the base plate (101) is configured with a first provision (104) to receive the IC chip (102) and a second provision (105) to receive the coil (103).

3. The system (200) as claimed in claim 1, wherein the tensioner unit (106) comprises at least one first actuator (110) connected to each of the pair of contact pads (107), wherein the at least one first actuator (110) is configured to displace the pair of contact plates (107) relative to each other between an open position and a gripping position.

4. The system (200) as claimed in claim 1, wherein the tensioner unit (106) comprises at least one second actuator connected to a base position of the at pair of contact pads (107), wherein the at least one second actuator is configured to displace the pair of contact pads (107) between the first position (FP) and the second position (SP).

5. The system (200) as claimed in claim 1, wherein the cutter unit (108) comprises of at least one blade (109) connected to the at least one third actuator (111) to trim the extending portion of leads of the coil (103) after joining.

6. The system (200) as claimed in claim 1, wherein the at least one first actuator (110), the at least one second actuator and the at least one third actuator (111) are one of pneumatic and hydraulic actuators.

7. A method for manufacturing a radio frequency identification (RFID) tag, the method comprising:
displacing, a pair of contact pads (107) of a tensioner unit (106) from a first position (FP) to a second position (SP) to maintain contact of the leads of a coil (103) with a conductive pads of an IC chip (102), wherein the leads of the coil (103) is received between the pair of contact pads (107) for joining;
cutting, an extending portion of leads of the coil (103) after joining by a cutter unit (108), wherein the cutter unit (108) is fixed to the base plate (101) adjacent to the tensioner unit (106).

8. The method as claimed in claim 7, wherein the tensioner unit (106) aids in stiffening the leads of the coil on the IC chip (102) to effectively join the IC chip (102) and the coil (103).

9. The method as claimed in claim 7, wherein the joining operation is one of heat staking, welding, soldering and the like.

10. The method as claimed in claim 7, wherein the at least one first actuator (110), the at least one second actuator and the at least one third actuator (111) are configured to actuate in a sequential order to complete the stiffening and cutting operations.