CA2099732A1

CA2099732A1 - Eas tag with mechanically vibrating magnetic element and improved housing and method of making same

Info

Publication number: CA2099732A1
Application number: CA002099732A
Authority: CA
Inventors: Robert J. Sanford; John Kowalczyk; John Douglas Wulf
Original assignee: Sensormatic Electronics Corp
Current assignee: Sensormatic Electronics Corp
Priority date: 1992-10-16
Filing date: 1993-06-29
Publication date: 1994-04-17
Also published as: MX9306093A; EP0592780A3; TW226051B; US5357240A; AU4152693A; BR9303271A; EP0592780A2; JPH06208687A

Abstract

ABSTRACT OF THE DISCLOSURE
An EAS tag comprising a tag body having a central region, side wall regions connected to and integral with the central region and flap regions connected to and integral with the side wall regions. The tag body has fold lines at the junctions of the central and side wall regions and at the junctions of the side wall regions and the flap regions. By folding the tag body along these fold lines and, in the course of the folding procedure, inserting a first magnetic element, a substantially closed box-like housing with the first magnetic element loosely housed therein is formed.

Description

2099732 ~

_ack~round of th~ Invention This invention relates to tags for eleetronic article surveillance (EAS) systems and, in particular, to EAS tags utilizing magnetically vibrating magnetic elements. I
U.S. patents 4,510,489 and 4,510,490 disclose tags and ¦
tag structures and an EAS system in which the tags are attached to articles in order to protect the articles from theft. In the system of these patents, each EAS tag contains a first magnetic element which mechanically vibrates at a predetermined frequency in response to an interrogation field at that frequency. This vibration alters the magnetic permeability of the first magnetic ¦
element, causing the magnetic element to produce a magnetic fleld !
at the predetermined frequency. This field can then be detected !
to sense the tag and, thus, the article carrying the tag.
In the EAS tag of the '489 and '490 patents, a ~econd semi-hard or bard magnetic element is also used in the tag. This ~econd magnetic element is placed in close proximity to ths first element and, when magnetized, biases or arms the first magnetic element so that it will vibrate in response to the interrogation i magnetic ~ield at the predetermined frequency. By demagnetizing I
the second magnetic element, the bias is removed from the ~ir6t magnetic element and it no longer resonates to produce a detectable magnetic ~ield. The tag can thus be activated and deactivated by magnetizing and demagnetizinq the second magnRtic element, respectively.
In the EAS tag of the '489 and '4~0 patents, it i8 ~: :- .: . : , ,, : ~
: , - , . . .

~ 2099732 -) 1 essential that the first magnetic element be housed in a manner which allows it to mechanically vibrate. It is also essential that the second magnetic element be correctly situated and held in the tag in appropriate proximity to the first magnetic element, but not so as to restrict the first magnetic element's vibration. Failure to meet these requirements causes the vibration of the first magnetic element to be adversely affected, thereby preventing the tag from satisfying the desired amplitude - ~ ;
and frequency performance criteria.
In present EAS tags of this type, the tags are formed from a plastic material which carries a heat seal coating. This material is first subjected to a thermoforming process to form a rectangular box-like housing with an open top bordered by a surrounding flange. The first magnetic element is then inserted in the housing through the open top and a plastic sheet is placed over the top and heat sealed or laminated to the border flange to close the housing and loosely encase the first magnetic element.
The second magnetic element is adhesively ecured to a ! ~ -first side of a carrier whose second side carries an adhesively attached peelable liner. The carrier first side is laminated or otherwise secured to the plastic sheet including the part of the sheet laminated to the housing flange. With the second magnetic elem~nt thus secured via the carrier to the housing, the t~g i8 complete. Wben using the tag, the liner is peeled from the carrier and the exposed adhesive surface pressed against the article, thereby securing the tag and article together.

' ., ~, 2099732 ~

While the aforesaid tag has proved successful, there are certain ~eatures of the tag which limit its usefulness. For example, the flange of the housing, while needed to secure the plastic sheet closing the open end of the housing, increases the ¦
housing size and for many applications is aesthetically unattractive. This prevents use of the tag wlth certain types of articles and, hence, in certain markets.
Il Also, the thermoforming and laminating procedures carried out in fabricating the tag can result in bonding of the first magnetic element to the heat seal coatings of the tag body.¦
I~ this occurs, the required mechanical vibration of the first magnetio element may be restriated and the resultant tag may not perform acceptably. Tags in which this happens have to be discarded. ~his results in process inefficiencies and material i! loss.
~ urthermore, the heat seal coating of the flange of the tag body remains soft after the tag manufacture is completed.
As a result, during shipment of the tag, the first element ~ay become attached or lodged against the coating. In such case, the~
tag will not perform satisfactorily, resulting in the return of the tag by the purchaser and reduced confidence of the purchaser in the produot.
It is therefore an object of the present invention to provide an EAS tag oP the above-type which does not suffer from the drawbacks of the prior tags.
It is a further ob~ect of the present invention to .

provide an EAS tag of the above-type which is smaller in size and¦
aesthetically more pleasing. ¦
It is a further object of the present invention to provide an EAS tag of the above-type which is such that the first magnetic element of the tag is less likely to be hindered by the tag body.
It is a further object of the present invention to provide an apparatus and method for making a tag meeting the above-mentioned ob~ectives. ¦

~ummary_of tke Invention ¦
In accordance with the principles of the present invention, the above and other ob~ectives are realized in a tag comprising a tag body having a central region, side wall regions connected to and integral with the central region and flap regions connected to and integral with the side wall regions.
The tag body has fold lines at the ~unctions of the central and side wall regions and at the ~unotions of the side wall regions and the flap regions. By folding the tag body along these fold lines and, in the course of the folding procedure, inserting the I
first magnetic element, a ~ubstantially closed box-like housing with the first magnetic element loosely housed therein is formed.
In carrying out the forming and folding operation, the side wall regions are rai~ed to an upstanding position, the first element is then placed on the central region and the flaps folded together to close the opening above the side walls. ~he closed ':

r, i ,.. , . , . . , . , , ., . ,, :.. . , . ,,,, . , , . : , , ., . , -~: '' ',, . ,: '. . '' . ~ , . . . .

2099732 ~ I

flaps thus form a cover facing the central region and spaced therefrom by the height of the side wall regions. The closed box-like housing thus results.
To complete the tag, a carrier carrying the second magnetic element is adhesively secured on one side to the cover formed by the flaps. This leaves accessible a peelable liner on the second side of the carrier 50 that it can be peeled off to expose an adhesive layer ~or securing the tag to an article.
A method and apparatus are also disclosed for forming the tag in which a sequence of folding and forming procedure~
using mating mandrels and dies at different stations are carried ¦
out on a single sheet or strip of material. These forming and folding procedures create the fold lines in the strip and told the strip along these lines to develop the box-like tag housing with the first magnetic element housed therein. Also, at other stations, procedures for applying adhesive and the second magnetic element to the peelable liner are carried out to for~ ~, the carrier. The formed carrier and tag housing are then brought to a common station and ~oined together to complete the tag~ In the method and apparatus disclosed, multiple tags are formed with~
each procesæing cycle.

Brief Description of the Drawinqs The a~ove and other features and aspect~ of the present invention will become more apparent upon reading the following detailed description in conjunction with the accompanying , - : . . i . . , ~ ,,, . :: " ' ~ 2 0 9 9 7 3 2 '~

drawings, in which:
FIG. 1 shows a plan view of an unfolded tag body of a I EAS tag in accordance with the principles of the present ¦
' invention;
" FIG. 2 shows a perspective view of the tag body of ~IG.
1 after a fir~t folding procedure;
i! FIG. 3 shows in perspective view the tag body of FIGS.
2 after a second ~olding procedure and after insertion of a I) first magnetic element;
;! FIG. 4 shows the tag body of FIGS. 1-3 after a third -folding procedure;
FIG. 5 shows the tag body of FIGS. 1-4 after a fourth fold~ng procedure;
. FIG. 6 shows the tag body of FIG~ 5 to which a carrier il for a second magnetic ele~ent has been affixed to form a , completed tag;
FIGS. 7-9 show various views of an apparatus for . fabricating multiple tags of the invention ln accordance with the;
forming procedurs described in connection with FIGS. 1-6;
FIG. lO shows a segment of material af er being su~ected to a die punch operation in the apparatus o~ FIGS. 7-9;
FIG. 11 shows the segment of material of FIG. lO after being further sub~ected to a die cutting operation in the apparatus of FIGS. 7-9;
FIG. 12 show part of a die cavity assembly used in the .
apparatus of FIGS. 7-9; -_ 7 _ .: .

: ' :.

~ 2~99732 FIGS. 13 and 14 shows cross sections of a die cavity ofl the die cavity assembly of ~IG. 12;
FIG. 15 shows a complete die cavity assembly of the apparatus of FIGS. 7-9;
FIG. 16 shows a cross section through a section 16-16 of the die cavity assembly of FIG. 15;
FIGS. 17-18 show schematically details of the e~ector asæembly of the apparatus of FIGS. 7-9;
FIGS. 19-21 show a part of a carrier being formed by the apparatus of FIGS. 7-9 at various stages of formation; and FIGS. 22-23 show completed tags formed by the apparatus of FIGS. 7-9.
. FIG. 24 shows an EAS &ystem using a taq as shown in ¦ -FIG. 6.
! i FIGS. 25A-25C show views of a mandrel head used with ¦
the ~ie cavity assembly of the apparatus of FIGS~ 7-9.
FIGS. 2SA-26C show views of a further mandrel head usedj with the die cavity assembly of the apparatus of FIGS. 7-9.

Detailed Description FIG. 1 shows a thin sheet or strip of material 1 which can be used to form a box-like tag body 10 (see, FIG. 5~ of an EAS tag 20 (see, FIG. 6) in accordance with the principles of the present invention. The material used for the strip 1 can be a bendable, relatively stiff plastic or paper-like ma~erial. A
typical material might be, for example, polyvinylchloride (PVC).

,", ~ 2099732 As shown, the strip 1 is hexagonal in configuration with two equal length longer sides s~, s2 and four equal length shorter sides S3, S4, S5 and s6. Each of the sides S3-S6 has a notch 2 at about midway along its length. The notches 2 facilitate the bending of the strip 1 to form a first set of bend lines bl-b4 and a second set of bend lines b5-b8. These bend lines, in turn, segment the sheet into a central region lA, side ¦i wall regions lB-lE contiguous and integral with the central region and flap regions lF-lI contiguous and integral with the !
side wall regions lB-lE, re6pectively.
As shown, the central r~gion lA and the side wall regions lB-lE are rectangular, the flap regions lG and lI are trapezoidal and the flap regions lF and lH are triangular.
Moreover, the notches 2 are L shaped with equal ~ides or legs and il positioned such that the sides of each trapezoidal flap and the ¦
! sides of each triangular flap are all equal. With the reg~ons and the bend lines of the strip 1 so de~ined, the strip 1 can be I
formed into a box-like tag body enclosing a ~irst magnetic element, as will be di~cussed more fully below in connection with;
the forming steps schematically illustrated in FIGS 2-6.
More particularly, FIG. 2 shows the sheet 1 after being sub~ected to a die and mandrel forming operation to form the ~irst set of bend lines b5-b8 defining the flaps regions lF-lI.
In this case, a die and a cooperating or mating flat mandrel having width and length dimensions W~ and L~, act on the strip 1 to create the bend lines and flap regions which extend outwardly 2~99732 !

from the sheet, as shown in FIG. 2.
After this first forming and bending operation, a mechanically vibratable first magnetic element 3 of width and length dimension W3 and ~ is placed against the central region lA. The magnetic element 3 ¢an comprise a ferromagnetic material ~e.g., a magnetostrictive ~erromagnetic material) of the type described in the aforementioned '489 and '490 patents, the teach~ngs of which are incorporated herein by reference. A
second die a~d mandrel operation is then performed. In this situation, the die and its ~ating flat mandrel haye width and length dimensions W2 and ~j. As a result, they create the further bend lines bl-b4 in the strip 1 which together with the previously created bend lines b5-b8 define the cide wall regions lB-lE.
The resultant form of the strip 1 is as shown in FIG.
3. As can be seen, the side wall regions lB-lE and the flap regions lF-lI are upstanding and the first magnetic element 3 lies on the central region lA. By making the dimensions W3 and ¦
o~ the first magnetic element 3 less than the dimensions W
and ~j of the central region lA, the first magnetic element 3 is spaced from and free of the side wall regions lB-lE. The first ~ -magnetic element is thus able to expand and contract without hinderance from the side wall~ of the strip 1, as is required for its mechanical vibration.
Also, the hei~ht H of the side wall regions lB-lE
(determlned by the length o~ the side~ or legs of the notches 2) 2099732 -~
'. .
is made larger than the thickness t of the first magnetic element 3. This also prevents the flap regions from restricting movement of the element when the flaps are closed as descri~ed more fully below. ! ~
With the 6trip 1 held in a die of the same dimensions as that used in the immediately preceding operation, a further die and mandrel operation i6 performed. In this case, the mandrel used has flat sides that are angled outwardly at a 45 angle. These sides terminate at an outward end which ha~ width ¦
and length dimensions W4 and L4 that are slightly less than W2 and !
1~, respectively. As a result, the mandrel acts on the side wallc lB-IE of the strip 1 to cause overbending at the bend lines;
bl-b4. This results in the flaps and their contiguous side wall~ ¦
being bent inwardly at these bend lines. This brings the flaps and side walls toward each other and partially clo~es the open area above the side walls and flaps. FIG. 4 depict~ thi~ ¦
situation In a final die and mandrel operation, the strip 1 is i1 again held in a die of the same dimensions as in the previous two~
operations~ In this case, a flat mandrel with width and length dimen~ions also slightly les~ than W2 and L~, re~pectively, is employed. This mandrel acts on the outer surfaces of flaps 1F-lI to cause overbending at the bend lines b5-ba. This urges the partially closed flaps lF-lI further together until they sub~tantially mate and close the openin~ above the now upstanding side wall region~ lB-lE. The mandrel ic also slightly ~houldered in the co~figuration of the clo~ed flaps to prevent overlapping -- 11 -- , :, 2 ~99732 I

of the flaps when they become closed.
In this position, the flaps define a cover lOA which i~ faces and is spaced by the side wall height H from the central region lA and the magnetic element 3. This results in a closed rectangular box-like tag body 1o as shown in FIG. 5 in which tbe first magnetic element 3 is loosely housed -~ithin the body 60 as " to be able to undergo mechanical vibration.
The tag body 10 of FIG. 5 is formed into a completed ¦! tag as shown in FIG. 6 by seouring a carrier 11 to the body. ~he l carrier 11 includes a liner 12 which carries on one side 12A a i first layer of adhesive 13. The adhesive layer 13 has length and width dimensions ~ and W2 so as to encompass the cover lOA
¦ defined by the closed flaps lF-lI of the tag body 10.
,~ A semi-hard or hard second magnetic element 14 of the type deæcribed in the '4~9 and '490 patents for biasing the li magnetic element 3 so it can mechanically vibrate is secured to the adhesive layer 13. The magnetic element 14 is of length and width dimension slightly less than that of the adhesive layer. Ai , second adhesive layer 15 of dimension similar to that of the , layer 13 overlies the second magnetic element 14 and the portion , of the layer 13 extending beyond the magnetic element.
The carrier 11 is affixed to the tag body 10 by pressing the adhesive layer 15 onto the cover lOA. This ensures that the ~laps lF-lI defining the cover are held in closed position and also fills any void areas which may exist between the flaps.

- ~ , . . .

2~99732 1 -: .
When the finished tag 20 is to be used, the liner 12 is removed or peeled from the adhesive layer 13, leaving the layer exposed. The layer 13 is then pressed against the article receiving the tag 20 and the tag thereby secured to the article.
As can be apprecia ed, the completed tag 20 of FIG. 6 has straight side wall regions lB-lE which define the external limits of the tag without the presence of a surrounding flange.
Thi6 gives the tag an aesthetically pleasing streamlined appearance, making it more acceptable for use in EAS
applications.
Furthermore, the tag body 10 is of one-piece or -~
integral folded construction and does not require tha use of thermoforming or heat sealing procedures during formation.
Accordingly, the first magnetic element 3 is not exposed to heat sealed surfaces to which it can attach or become lodged. The ability of the element 3 to vibrate is thus not aompromised by the tag body or the ormation process. As a result, an overall more acceptable tag 20 from a visual and performance standpoint i8 realized- !
While the method of fabricating the tag 20 has been illustrated above in terms of fabricating a single tag, FIGS. 7-9j show an assembly 70 which is adapted to extend the procedure to multiple tag production. In the assembly 70, a continuous length of bendable, relatively stiff plastic or paper-like material 101 is fed from a roll 102 and pulled to a punching station 72. At the punching station, a predefined segment lOlA of the conveyed . .
., .

. , . . ..... , . ~ . . , , ~.' .: , , . , ` . . , ` .

2099732^;

material is punched with an array of square punches 72A.
; As shown in FIG. 1o, ~hese punches create rows and il columns of square holes 2A in the segment of material lOlA. The ¦
;j holes 2A, in turn, are used to form the notches 2 in a plurality ¦
1! f strips 1 to be cut or punched from the segment lOlA.
'! From the punch station 72, the continuous web of ! ¦ material 101 is pulled to bring the punched segment lOlA to an i¦ idle station 73 where the segment awaits entry onto a cutting i¦ station 74. At the cutting station 74, the punched segment lOlA
is cut by a predetermined cutting die 74A to create a plurality ~`
' of hexagonal strips 1 in the punched segment ~OlA. These strips ¦
1 are not cut completely through and remain loosely attached to ~i the segment lOlA whic~ itself is fully detached by the die 74A
,~ ~rom the remainder of the material 101. The cut segment lOlA
j with the strips l is shown in FIG. 11.
¦ Upon leaving the cutting station 74, the segment lOlA
is brought to a first station 81B of an indexing table assembly 5 , 81. The indexing table assembly 81 carries die assemblies 82 and ejector assemblies 83 (see, FIG. 9~ which are jointly indexed to various stations around the table. The table assembly 81 also supports at certain of these stations mandrel arrays for interacting with each die assembly 82 as it is indexed to the station.
FIG. 12 shows an enlarged partial view and FIG. 15 a complete view of one of the die a~semblies 82. As shown, the assembly 82 includ~s a cheokerboard array of like die cavities - 2099732 -` I
I
82A equal in number to the strips 1 formed on the material segment lOlA. Each die cavity 82A in the array is used to form a particular strip 1 into a tag body 10 as will be discussed in more detail below.
FIGS. 13 and 14 show cross sections through one of the ¦ die cavities 82A of the die assembly 82. These cross sections have been taken along the lines 13-13 and 14-14 of the die ¦ assembly as shown in FIG. 12. FIG. 16 shows a further cross-; section of a line of the die cavities taken along line 16-16 ln FIG. 15.
; As can be seen from these figures, each die cavity 82A
~, is stepped so as to define upper and lower sub-cavities 82~ and i 82C of length and width dimensions Ll and Wl and ~ and W2, respectively. These sub-cavities are used to form the sets of fold lines b5-b8 and bl-b4, respect1vely, in a corresponding strlp 1, as is discussed below. -! As is also shown, each die cavity 82A cooperates with pairs of e~ector heads 83~ and 83~ of the ejector assembly 83.
The latter assembly 83 is shown in greater detail in FIGS. 17 and¦
18 which depict the assembly along lines of die cavities 82A
extending along the width and length, respectively, of the die assembly 82. In FIG. 17, the ejector heads are in the down position and in FIG. 18 the ejector heads are in the up position.
As can be seen from these ~igures and FIG. 13, the ejector heads 83A and 8~B align with bores 82D and ~2E in the lower sub-cavity 82C and in their down position (shown in FIGS.

-`i 2099732 ~, 13, 16 and 17) form part of the base of the sub-cavity. A
further cavity 82F in the sub-cavity 82C is situated between the ! bores 82D and 82E and houses a magnetic piece 82G which is used for centering purposes, as will also be discussed below.
ji At the first station 81B of the table assembly 81, the ¦, segment lOlA with the cut strips 1 is placed over the die ¦l assembly 82 until each strip 1 is centered over one of the die cavities 82A. A first mandrel array 84 situated at the station 8?B comprises individual flat mandrels 84A arranged in checker~oard pattern corresponding to that of the die cavities 82A. Each die head of the array 84 furthermore has length and width dimensions Ll and Wl so that it can mate with the upper sub-cavity 82B of its die cavity 82A.
;j Upon actuation of the array 84, the mandrels 84A of thei I¦ array are moved downward, causing the respective strip~ 1 on the ¦
l~ segment lOlA to be detached from the seqment and forced into the I
respective sub-cavities 8~B. The strips are thereby folded and ii caused to take on the shape of the strip 1 shown in FIG. 2.
The mandrels of the array 84 are then retracted, allowing the table 81A of the assembly 81 to be indexed, to bring the die assembly 82 from the first station to a second station 81C of t~e table assembly 81. At the station 81C, first magnetic elements 3 are assembled into a checkerboard array similar to the array of die cavities 82A of the die assembly 82. The array of ~agnetic elements 3 is then lifted and brought to a position in which the array of elements aligns with the cavity array.

,~ 2~99732 ~ : -.
' Lowering of the array seats each magnetic element onto the , central surface of the strip 1 in a corresponding die cavity 82A. !
The magnetic elements are then released so that each now remains ¦
i, supported in its respective strip 1. Also, the force o~ the ¦¦ magnet 82G in each cavity 82A helps maintain the element 3 in a ¦I central position.
! ¦ Once the placement of the magnetic elements 3 is ¦¦ completed, the table 81A is again indexed moving the die assembly ¦¦ 82A ~rom the second station to a third station 81D where a ~econd¦
¦I folding operation on the strips 1 is to be carried out. At this ¦
! I
¦ station, a second checkerboard mandrel array 85 is provided for interacting with the die cavities 82A of the die assembly 82. In ! this case, each mandrel head 85A is flat with length and width Ij dimensions ~ and W2 50 as to be commensurate with the lower sub-¦¦ cav~ty 82C of the corresponding die cavity 82A. As a result, ¦ when the mandrel array 85 is lowered, each mandrel head mate~
¦~ with a corresponding sub-cavity 82C, thereby further foIding the , strip 1 in the cavity. This folding causes each strip to now take on the configuration shown in FIG. 3.
; After the array 85 completes the second folding i operation, the array is retracted and the table 81A again indexed, bringing the die assembly 82 from the third station to a - ~ourth station 81E At this station, a further checkerboard mandrel array 86 is provided for interacting with the array of die cavities 82A of the die assembly 82. As shown in FIGS. 25A-25C, each mandrel head 86A o~ the array 86 has flat sides angled -.

. . .~ ; . .

:- , . . ~ . , ~ . . . . . ... .

~ 2099732 - I
outwardly at 45. These sides terminate at their up ends to provide length and width dimensions slightly less than ~ and W2, ` respectively.
When the mandrel array 86 is lowered, each head 86A
! i comes in contact with the side walls lB-lE of the corresponding ! i strip 1. This causes overbending at the bend lines bl-b4. As a ¦! result, the parts of strip above the bend lines, i.e., the ¦I continguous, flap and side wall parts are urged together. The ! result!~nt strips 1, there~ore, are left in the dies 82A with the configuration as shown in FIG. 4.
After the mandrel array 86 completes its forming ii operation, the array ~8 retracted from the die assembly 82, il allowing the table 81 to be indexed from the fourth station to a ¦
li fifth statio~ 81F. At this station, ~nother checkerboard array of mandrels 87 ~iimilar to the array 86 is provided for interacting with the die ~,ssembly 82. In thi~i case, each ~andrel¦
head 87A i8 dimensioned similar to the heads in the array 86, ¦ ;
except that each head 1,s, flat with a slightly shouldered or raised pattern on the flat surface in the configuration of the flaps. This i8 illustrated in FIGS. 26A-26C, the shouldered pattern beinq shown as 87~ i When the array 86 is actuated, each mandrel head 87A
interacts with the outer surface of the partially closed flap regions of its corresponding strip 1 causing overbending at the bend lines b5-b8. Thi8, in turn, urges the flap regions together until they completely clo~e while the side walls remain ~ 2~99732 upstanding. The flaps as they close are prevented from overlapping by the shouldered pattern 87B. The resultant strip 1i , in each die cavity 82A thus takes on the box-like body form 10 , shown in FIG. 5 .
After the folding operation at the station 81F, the die assembly 82 thus holds in its die cavities 82A an array of tag I bodies 10. These tag bodies must now be provided with carriers ! 11 in order t~ complete each tag. To this end, the asse~bly 70 ¦ is ~urthel~ provided with a carrier forming assembly 91.
~i The carrier forming assembly 91 receives a release i~ liner 12 supplied from a continuous liner roll 94. The liner 12 ¦
, may comprise various materials. A typical material might ~e , craft paper having a silicone coating on one side corresponding i to the outer face or side 12A of the liner.
jl The continuous liner 12 is pulled to a first adhesive or gluing station 91A of the assembly 91. A~ this station an ; adhesive pattern comprised of successive rows and columns oP
spaced rectangular adhesive segments 13 is applied to the ~ide 12A of a segment 12B of the liner. Each adhesive segment 13 has , length and width dimensions ~ and W~ and thus is commensurate ' with the outside dimensions of one of the tag bodies 10 in the cavity assembly 82. Each segment 13 is further spaced horizontally by a distance L~-LI and vertically by a distance W2-Wl, from its adjacent segments. These distances correspond to the horizonal and vertical displacement of the cavities 82A from their ad~acent cavities in the assembly 82. The segment 12~ of - . " .

- ,, . , , :. . .

~ 2~99732 --j the liner 12 with the adhesive segments 13 applied is shown in FIG. 19.
. After undergoing the adhesive application at the i! station 91A, the liner 12 is again pulled bringing the segment i! 12B to a second station 91B. At this station, a second magnetic ¦
element 14 is applied to each of the adhesive segments 13 on the ¦ -~l liner ~egment 12B. Each element 14 has length and width!~ dimensions ~ and W3.
¦l ~ The second magnetic elements 14 are first arranqed by al j~ supply assembly 9~ into an array similar to the adhesive array of' :: segments 13. The supply assembly 96 then brings the array of magnetic elements over the liner segment 12B with the array of ! magnetic elements 14 aligned with the adhesive segment array.
i The magnetic elements 14 are then brought downward and pressed onto the corresponding adhesive segments 13 so as to adhere to , the segments. The resultant liner segment 12B with the magnetic , . ~ . ; .
i. elements 14 and adhesive segments 13 is shown in FIG. 20.
After the supply assembly 96 completes its operation, the liner 12 is pulled and segment 12B is carried to a further station 91C of the forming assembly 91. At this station, a further glue or adhesive segment array like the irst adhesive segment array is applied to the liner. Thus, an adhesive segment 15 is applied over and covers earh magnetic element 14 and its associated adhesive segment 13. The liner segment 12B after this second adhesive application is shown in FIG. 21.
once the liner segment 12B has received the second , . . . : , . . -2~99732 ..

adhesive segments, each laminate of liner 12, first adhesive . segment 13, second magnetic element 14.and second adhesive segment 15 defines a carrier 11. The array of carriers 11 i :~
defined by the liner segment 12B is then brought to a sixth li station 81G of the table 81. Also brought to this station by ¦¦ further indexing of the table 81A, is the die assembly 82 with ! ¦ the formed tag bodies lo which are to be joined to the carriers 11 to for~ completed tags 20.
.? pulling the liner 12 to bring the liner seg~ent 12B
to the station 81G, the liner is turned over so that the segment side 13A of the liner segment 12B with the carriers 11 faces .1 downwardly toward the cavity assembly 82 holding the tag bodies ! I lo. With the liner segment in this position each of the carriers ~ brought into alignment with one oP the cavities 82A. The ¦¦ e~ectors 83A and 83B of the e~ector assembly 83 are then actuated ! ¦ 80 as to bring the ejectors to their up position (see, FIG. 18).
.¦ This moves the tag bodies 10 in the corresponding cavities 82A ' ;
upward into contact with the adhesive segments 15 of the corresponding carriers 11. The tag bodies 10 thus adhere to the ~:~ . segments and are released from the cavities.
i, The resultant checkerboard pattern of completed tags 20.
on the liner segment 12B is shown in FIG. 22. In order to now also form completed tags using the empty intermediate carrier locations, the liner 12 is indexed backward one tag width and the : table 81A is indexed to bring another cavity assembly 82 with another checkerboard pattern of tag bodies 10 under the indexed i: ~ -~ 21 - ~
:~
: ~ :

-` 209~732 liner. Due to the indexing, the empty intermediate carrier locations of the liner segment 12B now align with the cavities 82A holding the tag bodies 10 of the further cavity assembly.
By actuating the ejectors accompanying this further cavity assembly, the tag bodies 10 held in the assembly are ~ecuxed to the adhesive segments 15 at the intermediate carrier locations. The resultant liner segment 12~ is shown in FIG. 2Z
and comprises a rectangular array of spaced completed tags 20.
Aft~r formation of the tag array 20, the liner 12 is ~ -pulled so that liner segment 12B is carried from the station 81G j to a storage station ~8 of the carrier forming assembly 91. At I ;
thiQ station, the liner segment 12B may be rolled or zig-zag folded with other segments of the liner 12 ~or storing purposes.
The stored segments may be later separated into individual tags or into ~roups of tags by suitable slitting of the liner in the spaces between the individual tags.
~ he apparatus 70 thus provides for continuous ~abrication of large quantities of tags 20 in an efficient and easy manner. -FIG. 24 shows an EAS system utilizing the tag 20 of FIG. 6. As shown, a transmitter 201 transmits a magnetic field ~ -at a predetermined frequency into an interrogation zone 202 in which an article 203 carrying a tag 20 is located.
The magnetic element 3 of tag 20 is adapted to be able to mechanically vibrate at the predetermined frequency and the magnetic element 14 of the tag i~ magneti~ed to bias the element . . .. .

' ~3 2~99732 ~ ~

3 so it can undergo such vibration. A receiver 204 receives magnetic energy or a magnetic signal at the predetermined ii frequency as a result of the interaction of the tag 20 With the ¦¦ field transmitted from the transmitter. As a result, the presence of the tag and, thus, the article 203 in the zone 202 can be detected. The transmitter 201 and the receiver 204 can be~
of the type described in the '489 and '490 patents.
In the embodiments of the invention discussed above, the tag 20 of i~!vention included a first magnetic element 3 ¦
housed within the box-like housing or body 10 and a second il magnetic element 14 for housing the first magnetic element 3 and j ~¦ carrled by carrier 11 secured to the outside of the body 10. It ~¦ is al80 within the contemplation o the invention that the tag be jl formed With second magnetic element arranged within the body 10 il in8tead of carried by the carrier 11. While this can be ~¦ accomplished in various ways, one way is to form the magnetic element 14 as part of the magnetic element 3 as, for example, a l; ~emi-hard or hard magnetic surface layer of the magnetic element 3. In such case, the carrier 11 could then be a simple la~inate of the liner 12 and an adhesive layer.
It should also be noted that in the description of the ~ apparatus o~ FIGS. 7-9, a continuous web of material 101 was I ~ pulled from a roll 102 and segments lOlA of the continuous roll :`
; were processed and then subse~uently cut in formlng the strips 1.
; The apparatus can also be constructed such that individual 5egments lOlA of material are f irst cut from the continUous web 209~732 ~ !

and the individual segments then processed. In this case, the cut segments would be processed in the same manner as they were I -when attached to the web.
jj In all cases it is understood that the above-described arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention. Numerous and varied other arrangements, can be readily devised in accordance with the principles of the present ' invention without c~eparting from the spirit and scope of the ¦, invention.

,-,, '

Claims

1. An EAS tag comprising:
a tag body including: a central region; side wall regions connected to and integral with the central region; first fold lines at the junctions of said central region and said side wall regions at which said side wall regions are folded so as to extend outward of said central region; flap regions connected to and integral with said side wall regions; and second fold lines at the junctions of said side wall regions and said flap regions at which said flap regions are folded so as to come together to form a closed cover facing and spaced from said central region;
thereby forming said tag body into a closed housing;
and a first magnetic element, said first magnetic element being capable of mechanically vibrating and being disposed said closed housing.

2. An EAS tag in accordance with claim 1 further comprising:
a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate;
and means for securing said second magnetic element to said tag body.

3. An EAS tag in accordance with claim 2 wherein:
said securing means secures said second magnetic element to said cover of said tag body.

4. An EAS tag in accordance with claim 3 wherein:
said securing means comprises: a peelable liner; and an adhesive means on one side of said peelable liner from which said peelable liner can be peeled;
said second magnetic element being secured to said adhesive means;
and said adhesive means securing said securing means to said cover of said tag body.

5. An EAS tag in accordance with claim 4 wherein:
said adhesive means is at least commensurate in extent to said cover of said tag body.

6. An EAS tag in accordance with claim 5 wherein:
said second magnetic element is of lesser extent than said adhesive means.

7. An EAS tag in accordance with claim 4 wherein:
said adhesive means includes: a first adhesive layer on said one side of said liner; said second magnetic element being adhered to said first adhesive layer; and a second adhesive layer overlying said second magnetic element and said first adhesive layer.

8. An EAS tag in accordance with claim 7 wherein:
said first and second layers are at least commensurate in extent to said cover of said tag body.

9. An EAS tag in accordance with claim 8 wherein:
said second magnetic element is of lesser extent than said first and second layers.

10. An EAS tag in accordance with claim 2 wherein:
said first magnetic element is a ferromagnetic element;

and said second magnetic element is a hard or semi-hard magnetic element.

11. An EAS tag in accordance with claim 10 wherein:
said first magnetic element is a magnetostrictive element.

12. An EAS tag in accordance with claim 1 wherein:
said first magnetic element has length and width extent less than the length and width extent of said central region and thickness extent less than the height of said side wall regions.

13. An EAS tag in accordance with claim 1 wherein:
said flap regions are of extent such that the edges of said flap regions mate when said flap regions are together forming said closed cover.

14. An EAS tag in accordance with claim 1 wherein:
said central region is rectangular having first and second opposing longer sides and first and second opposing shorter sides;
said side wall regions comprise first, second, third and fourth rectangular side wall regions, said first and second side wall regions being integral with said first and second longer sides of said central region and said third and fourth side wall regions being integral with said first and second shorter sides of said central region;
and said flap regions comprise first and second triangular flap regions integral with said third and fourth side wall regions, and third and fourth trapezoidal flap regions integral with said first and second side wall regions.

15. An EAS tag in accordance with claim 14 wherein:
said flap regions are of extent such that the edges of said flap regions mate when said flap regions are together forming said closed cover.

16. An EAS tag in accordance with claim 15 wherein;
the height of said side wall regions is equal.

17. An EAS tag in accordance with claim 16 wherein:
the length of the sides of said triangular and trapezoidal flap regions is equal.

18. An EAS tag in accordance with claim 1 wherein:
said tag body when unfolded forms a hexagonal strip having first, second, third, fourth, fifth and sixth sides, said first and fourth sides being opposing and parallel, said second and fifth sides being opposing and parallel, and said third and sixth sides being opposing and parallel, said second, third, fifth and sixth sides being of equal first length and said first and fourth sides being of equal second length greater than said first length, each of said second, third, fifth and sixth sides having an L shaped notch positioned and dimensioned such that the length of the side from one end to the point at which the legs of the L shaped notch intersect is equal to the length of the side from the other end to said point where the legs of the L shaped notch intersect.

19. An EAS tag in accordance with claim 18 wherein:
said second set of fold lines connect the points at which the legs of said L shaped notches intersect with said second, third, fourth and fifth sides;
and said first set of fold lines connect the points at which the legs of said L shaped notches intersect.

20. Apparatus for forming an EAS tag comprising:
die and mandrel assembly means for: folding a strip of material to form a first set of fold lines defining flap regions;
folding said strip of material to form a second set of fold lines defining side wall regions and a central region, said side wall regions being integral with said flap regions and said central region being integral with said side wall regions, said first set of fold lines being at the junctions of said flap regions and said side wall regions and said second set of fold lines being at the junctions of said side wall regions and said central region;
disposing a first magnetic element capable of mechanically vibrating in said central region; and folding said flaps to cause said flaps to come together to form a closed cover facing and spaced from said central region; thereby forming a closed housing with said first magnetic element held therein to define a tag body.

21. Apparatus in accordance with claim 20 further comprising:
means for forming a carrier including a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate;
and means for causing said carrier and said housing to be secured together.

22. Apparatus in accordance with claim 21 wherein:
said means for causing causes said carrier said cover of said housing to be secured together.

23. Apparatus in accordance with claim 22 wherein:
said carrier forming means includes: means for supplying a liner; means for applying an adhesive means to said liner and for enabling said second magnetic element to be adhered to said adhesive means;
and said means for causing causes said adhesive means of said carrier and said cover of said housing to be secured together.

24. Apparatus in accordance with claim 23 wherein:
said adhesive applying means includes: means for applying a first adhesive layer to said liner; means for enabling said second magnetic element to be adhered to said first adhesive layer; and means for applying a second adhesive layer over said second magnetic element and said first adhesive layer;
and said means for causing causes said second adhesive layer and said cover of said housing to be secured together.

25. Apparatus in accordance with claim 20 wherein:
said strip of material is hexagonal and has first, second, third, fourth, fifth and sixth sides, said first and fourth sides being opposing and parallel, said second and fifth sides being opposing and parallel, and said third and sixth sides being opposing and parallel, said second, third, fifth and sixth sides being of equal first length and said first and fourth sides being of equal second length greater than said first length, each of said second, third, fifth and sixth sides having an L shaped notch positioned and dimensioned such that the length of the side from one end to the point at which the legs of the L shaped notch intersect is equal to the length of the side from the other end to said point where the legs of the L shaped notch intersect.

26. Apparatus in accordance with claim 25 wherein:
said first set of fold lines connect the point at which the legs of said L shaped notches intersect with said second, third, fourth and fifth sides;
and said second set of fold lines connect the points at which the legs of said L shaped notches intersect.

27. Apparatus in accordance with claim 20 wherein:
said die and mandrel assembly means includes: a die cavity having upper and lower sub-cavities, said lower sub-cavity being of smaller dimension than said upper sub-cavity.

28. Apparatus in accordance with claim 27 wherein:
said lower sub-cavity includes a magnetic means.

29. Apparatus in accordance with claim 27 wherein:
said die and mandrel assembly means further includes:
a first die head of dimension equal to the dimension of said upper sub-cavity for interacting with said upper sub-cavity and said first strip to fold said strip to form said first set of fold lines, a second die head of dimension equal to the dimension of said lower sub-cavity for interacting with said lower sub-cavity and said strip to form said second set of fold lines; and one or more further die heads of dimension slightly less than the dimensions of said lower sub-cavities for interacting with said strip to fold said flap regions.

30. Apparatus in accordance with claim 29 wherein:
said one or more further die heads include a third die head of configuration so as to interact with the side wall regions of said strip to partially fold said flap regions and a fourth die head of configuration so as to interact with the outer surfaces of said flap regions to fully fold said partially folded flap regions to provide said cover.

31. Apparatus in accordance with claim 29 wherein:
said lower sub-cavity includes at least one bore;
and said apparatus further includes means in said bore for urging said strip from said die cavity.

32. Apparatus in accordance with claim 29 wherein:
said die and mandrel assembly means further includes:
an indexing table carrying said die head; and means for indexing said table to first, second and one or more further stations adjacent said table;
and said first, second and one or more further mandrels being situated at said first, second and one or more further stations, respectively.

33. A method of forming an EAS tag comprising the steps of:
folding a strip of material to form a first set of fold lines defining flap regions;

folding said strip of material to form a second set of fold lines defining side wall regions and a central region, said side wall regions being integral with said flap regions and said central region being integral with said side wall regions, said first set of fold lines being at the junctions of said flap regions and said side wall regions and said second set of fold lines being at the junctions of said side wall regions and said central region;
disposing a first magnetic element capable of mechanically vibrating in said central region;
and folding said flaps to cause said flaps to come together to form a closed cover facing and spaced from said central region;
thereby forming a closed housing with said first magnetic element held therein to define a tag body.

34. A method in accordance with claim 33 further comprising:
causing a carrier including a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate and said tag body to be secured together.

35. A method in accordance with claim 34 wherein:
said causing step is carried out by causing said carrier and said cover of said tag body to be secured together.

36. A method in accordance with claim 35 wherein:
said causing step is carried out by causing an adhesive layer included on said carrier and said cover of said tag body to be secured together.

37. A method in accordance with claim 34 further comprising:
forming said carrier including: applying a first adhesive layer to a liner; applying said second magnetic element to said first adhesive layer; and applying a second adhesive layer over said first adhesive layer and second magnetic element.

38. A method in accordance with claim 37 wherein:
said causing step is carried out by causing said second adhesive layer of said carrier and said cover of said tag body to be secured together.

39. A method in accordance with claim 33 wherein:
said strip of material is hexagonal and has first, second, third, fourth, fifth and sixth sides, said first and fourth sides being opposing and parallel, said second and fifth sides being opposing and parallel, and said third and sixth sides being opposing and parallel, said second, third, fifth and sixth sides being of equal first length and said first and fourth sides being of equal second length greater than said first length, each of said second, third, fifth and sixth sides having L shaped notches positioned and dimensioned such that the length of the side from one end to the point at which the legs of the L shaped notch intersect is equal to the length of the side Prom the other end to said point where the legs of the L shaped notch intersect.

40. A method in accordance with claim 39 wherein:
said first set of fold lines connect the points at which the legs of said L shaped notches intersect with said second, third, fourth and fifth sides;
and said second set of fold lines connect the points at which the legs of said L shaped notches intersect.

41. An EAS system comprising:
means for transmitting a first magnetic field into an interrogation zone;
an EAS tag comprising: a central region; side wall regions connected to and integral with the central region; first fold lines at the junctions of said central region and said side wall regions at which said side wall regions are folded so as to extend outward of said central region; flap regions connected to and integral with said side wall regions; and second fold lines at the junctions of said side wall regions and said flap regions at which said flap regions are folded so as to come together to form a closed cover facing and spaced from said central region;
thereby forming said tag body into a closed housing; and a first magnetic element, said first magnetic element being capable of mechanically vibrating and being disposed said closed housing;
and means for receiving a magnetic signal resulting from the interaction of said first magnetic field and said EAS
tag for detecting the presence of said EAS tag in said interrogation zone.

42. An EAS system in accordance with claim 41 wherein:
said EAS tag further comprises:
a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate;
and means for securing said second magnetic element to said tag body.

43. An EAS system in accordance with claim 42 wherein:
said securing means secures said second magnetic element to said cover of said tag body.

44. A method of operating an EAS system comprising:
transmitting a first magnetic field in an interrogation zone;
situating an EAS tag in said interrogation zone, said EAS tag comprising: a central region; side wall regions connected to and integral with the central region; first fold lines at the junctions of said central region and said side wall regions at which said side wall regions are folded so as to extend outward of said central region; flap regions connected to and integral with said side wall regions; and second fold lines at the junctions of said side wall regions and said flap regions at which said flap regions are folded so as to come together to form a closed cover facing and spaced from said central region;
thereby forming said tag body into a closed housing; and a first magnetic element, said first magnetic element being capable of mechanically vibrating and being di posed in said closed housing;
and receiving a magnetic signal resulting from the interaction of said first magnetic field and said EAS tag for detecting the presence of said EAS tag in said interrogation zone.

45. A method in accordance with claim 44 wherein:
said EAS tag further comprises: a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate;
and means for securing said second magnetic element to said tag body.

46. An EAS tag in accordance with claim 1 further comprising:
a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate, said second magnetic element body disposed in said housing.

47. An EAS tag in accordance with claim 46 wherein:
said second magnetic element forms as a part of said first magnetic element.

48. An EAS tag in accordance with claim 47 wherein:
said second magnetic element forms a surface portion of said first magnetic element.

49. An EAS tag in accordance with claim 1 further comprising a peelable liner;
an adhesive means on one side of said peelable liner from which said peelable liner can be peeled; and said adhesive means being secure to said cover of said tag body.

50. An EAS tag in accordance with claim 49 further comprising:

a second magnetic element capable of enabling said first magnetic element to mechanically vibrate, said second magnetic element being formed as part of said magnetic element.

51. A method in accordance with claim 30 wherein:
a second magnetic element capable of enabling said first magnetic element to be able to magnetically vibrate is disposed in said closed housing.

52. A method in accordance with claim 51 wherein:
said second magnetic element forms as a part of said first magnetic element.

53. A method in accordance with claim 51 wherein:
said second magnetic element forms a surface portion of said first magnetic element.

54. An EAS system in accordance with claim 41 wherein:
said EAS tag further comprises:
a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate, said second magnetic element being disposed in said housing.

55. An EAS system in accordance with claim 54 wherein:
said second magnetic element forms as a part of said first magnetic element.

56. An EAS system in accordance with claim 55 wherein:
said second magnetic element forms a surface portion of said first magnetic element.

57. A method of operating an EAS system in accordance with claim 54 wherein:

said EAS tag further comprises:
a second magnetic element capable of enabling said first magnetic element to be able to mechanically vibrate, said second magnetic element being disposed in said housing.

58. A method of operating an EAS system in accordance with claim 57 wherein:
said second magnetic element forms a part of said first magnetic element.

59. A method of operating an EAS system in accordance with claim 58 wherein:
said second magnetic element forms a surface portion of said first magnetic element.