Surgical sponges with flexible rfid tags

Abstract

A surgical sponge is provided, having a radiofrequency (RF) tag positioned interior thereto. The RF tag has a base layer with at least one tab projecting from an outer perimeter of thereof. The RF tag has a first protective layer with at least one tab projecting from the outer perimeter of the RF tag and generally aligned with the at least one tab of the base layer and an RF identifier laminated between the base layer and the first protective layer. The RF identifier has an antenna, and an electrically responsive member. The antenna can be a metal foil loop antenna etched on to the base layer. The RF identifier can include additional metal foil provided on the base layer when the metal foil loop antenna is etched on to the base layer, the additional metal foil configured to enhance x-ray opacity of the sponge.

What is claimed is: 
     
         1 . A surgical sponge, comprising:
 a sponge body; and   a radiofrequency (RF) tag positioned interior to the sponge body, the tag comprising:
 a radiofrequency (RF) identifier comprising an antenna and an electrically responsive member, 
 a base layer having at least one tab projecting from an outer perimeter of the RF identifier, 
 the base layer comprising a first polymeric film material, 
 a first protective layer having at least one tab projecting from the outer perimeter of the RF identifier and generally aligned with the at least one tab of the base layer, the first protective layer comprising a second polymeric material, 
 wherein the RF identifier is laminated between the base layer and the first protective layer. 
   
     
     
         2 . The surgical sponge of  claim 1 , wherein the antenna is at least one of an etched metal foil antenna and a wound wire antenna. 
     
     
         3 . The surgical sponge of  claim 1 , wherein the electrically responsive member includes at least one of programmable integrated circuit (IC) chip, a capacitor, and a resistor. 
     
     
         4 . The surgical sponge of  claim 1 , wherein the tag includes a second protective layer positioned opposite to the first protective layer, the second protective layer comprising a polymeric film material, the second protective layer and the first protective layer substantially enclosing the base layer and the identifier. 
     
     
         5 . The surgical sponge of  claim 5 , wherein the polymeric film material is a flexible tear-resistant film. 
     
     
         6 . The surgical sponge of  claim 1 , wherein the tag is attached to the sponge body at a location corresponding to the at least one tab of each of the first protective layer and the base layer. 
     
     
         7 . The surgical sponge of  claim 6 , wherein the tag is attached to the sponge body by at least one of sewing and heat bonding. 
     
     
         8 . The surgical sponge of  claim 7 , wherein fibers of the surgical sponge are pressed into the polymeric film material that has been heated and partially melted, creating a heat bond between the fibers and the polymeric film material. 
     
     
         9 . The surgical sponge of  claim 1 , wherein the at least one tab of each of the first protective layer and the base layer project radially outward beyond an edge of the sponge body when the tag is attached to the sponge body. 
     
     
         10 . The surgical sponge of  claim 1 , wherein one or more of the base layer and the one or more polymeric protective film layers is made of colored polymeric film for so as to contrast with blood and tissue. 
     
     
         11 . The surgical sponge of  claim 1  wherein the one or more of the polymeric protective film layers is configured to fluoresce when illuminated by a light source at a predetermined wavelength. 
     
     
         12 . The surgical sponge of  claim 1 , wherein the one or more polymeric protective film layers are hydrophobic relative to the surgical sponge, the one or more polymeric protective film layers being configured for repelling blood. 
     
     
         13 . A surgical sponge, comprising:
 a sponge body; and   a radiofrequency (RF) tag attached within an interior portion of the sponge body, the tag comprising:
 a base layer, 
 a radiofrequency (RF) identifier comprising a metal foil antenna etched on to the base layer and an electrically responsive member, 
 additional metal foil remaining on the base layer when the metal foil antenna is etched on to the base layer, the additional metal foil configured to enhance x-ray opacity of the surgical sponge, 
 a first polymeric film protective layer with the metal foil antenna and the electrically responsive member being laminated between the first protective film layer and the base layer, 
 wherein each of the base layer and the protective film layer has one or more tabs that project outward from an outer perimeter of the RF identifier. 
   
     
     
         14 . The surgical sponge of  claim 13 , wherein the electrically responsive member includes at least one of programmable integrated circuit (IC) chip, a capacitor, and a resistor. 
     
     
         15 . The surgical sponge of  claim 13 , wherein the tag includes a second protective layer positioned opposite to the first protective layer, the second protective layer comprising a polymeric film material, the second protective layer and the first protective layer substantially enclosing the base layer, the metal foil antenna and the electrically responsive member. 
     
     
         16 . The surgical sponge of  claims 13 , wherein the tag is attached to the sponge body at a location corresponding to the at least one tab of each of the first protective layer and the base layer by at least one of sewing and heat bonding. 
     
     
         17 . The surgical sponge of  claim 14 , wherein fibers of the surgical sponge are pressed into the polymeric film material that has been heated and partially melted, creating a heat bond between the fibers and the polymeric film material. 
     
     
         18 . The surgical sponge of  claim 13 , wherein one or more of the base layer and the one or more polymeric protective film layers is made of colored polymeric film for so as to contrast with blood and tissue. 
     
     
         19 . The surgical sponge of  claim 13  wherein the one or more of the polymeric protective film layers is configured to fluoresce when illuminated by a light source at a predetermined wavelength. 
     
     
         20 . The surgical sponge of  claim 13 , wherein the one or more polymeric protective film layers are hydrophobic relative to the surgical sponge, the one or more polymeric protective film layers being configured for repelling blood. 
     
     
         21 . A surgical sponge, comprising:
 a sponge body; and   a radiofrequency (RF) tag positioned interior to the sponge body, the tag comprising:
 a base layer comprising a first polymeric film material, 
 a radiofrequency (RF) identifier comprising at least an antenna and an electrically responsive member attached to the base layer, 
 the base layer having at least one tab projecting from an outer perimeter of the RF identifier, 
 a first protective layer having at least one tab projecting from the outer perimeter of the RF identifier and generally aligned with the at least one tab of the base layer, the first protective layer comprising a second polymeric material, and the RF identifier is laminated between the base layer and the first protective layer, 
 wherein one or more of the base layer and the one or more polymeric protective film layers is made of colored polymeric film so that it visually contrasts with blood and tissue. 
   
     
     
         22 . The surgical sponge of  claim 21 , wherein the antenna is at least one of an etched metal foil antenna and a wound wire antenna. 
     
     
         23 . The surgical sponge of  claim 21 , wherein the electrically responsive member includes at least one of programmable integrated circuit (IC) chip, a capacitor, and a resistor. 
     
     
         24 . The surgical sponge of  claim 21 , wherein the tag includes a second protective layer positioned opposite to the first protective layer, the second protective layer comprising a polymeric film material, the second protective layer and the first protective layer substantially enclosing the base layer and the identifier. 
     
     
         25 . The surgical sponge of  claim 21 , wherein the tag is attached to the sponge body at a location corresponding to the at least one tab of each of the first protective layer and the base layer. 
     
     
         26 . The surgical sponge of  claim 25 , wherein the tag is attached to the sponge body by at least one of sewing and heat bonding. 
     
     
         27 . The surgical sponge of  claim 26 , wherein fibers of the surgical sponge are pressed into the polymeric film material that has been heated and partially melted, creating a heat bond between the fibers and the polymeric film material. 
     
     
         28 . The surgical sponge of  claim 21 , wherein the at least one tab of each of the first protective layer and the base layer project radially outward beyond an edge of the sponge body when the tag is attached to the sponge body. 
     
     
         29 . The surgical sponge of  claim 21  wherein the one or more of the polymeric protective film layers is configured to fluoresce when illuminated by a light source at a predetermined wavelength. 
     
     
         30 . The surgical sponge of  claim 21 , wherein the one or more polymeric protective film layers are hydrophobic relative to the surgical sponge, the one or more polymeric protective film layers being configured for repelling blood.