Electronic article surveillance tag with thread antenna

Abstract

An article surveillance tag includes: a fabric material defining a top layer and a bottom layer; an antenna comprising: an electrically-conductive thread interfixed into one of the top layer or the bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal filament and a metal-coated non-metallic filament; and an induction loop overlapping with the electrically-conductive thread, wherein the induction loop comprises metallic material; and a radio frequency identification device electrically coupled with the induction loop.

Description

ELECTRONIC ARTICLE SURVEILLANCE TAG WITH THREAD ANTENNACROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 614,021 entitled “ELECTRONIC ARTICLE SURVEILLANCE TAG WITH THREAD ANTENNA” filed December 22, 2023, which is assigned to the assignee hereof, and incorporated by reference in its entirety as if fully set forth herein.TECHNICAL FIELD

[0002] The present disclosure generally relates to electronic article surveillance, and more particularly, to an article surveillance tag with an antenna interfixed into a fabric of the tag.BACKGROUND

[0003] Merchandise items offered by a vendor may be sold in one or more "brick-and-mortar" stores. Customers may enter the one or more brick-and-mortar stores of the vendor and purchase the merchandise items, however, often times the vendor may encounter loss due to theft.

[0004] In an effort to reduce theft of merchandise items, many vendors utilize loss-prevention or security measures to minimize the amount of stolen merchandise. Some loss-prevention measures include security monitoring, inventory tracking, and electronic article surveillance. In particular, electronic article surveillance may include using a radio frequency identification (RFID) label or tag attached to the merchandise. RFID article surveillance tags, and their associated antennas, may become damaged or inoperable if folded or bent. Thus, there is therefore a need for a flexible article surveillance tag.SUMMARY

[0005] The following presents a simplified summary of one or more aspects in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later.

[0006] According to one example, an article surveillance tag comprises a fabric material defining a top layer and a bottom layer; an antenna comprising: an electrically-conductive thread interfixed, e.g., sewn or woven, into one of the top layer or the bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal filament and a metal-coated non-metallic filament; and an induction loop overlapping with the electrically-conductive thread, wherein the induction loop comprises metallic material; and a radio frequency identification device electrically coupled with the induction loop.

[0007] Another example aspect includes an article surveillance tag wherein the metal-coated non- metallic filament comprises a metal-coated non-metallic multifilament.

[0008] Another example aspect includes an article surveillance tag wherein the electrically- conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

[0009] Another example aspect includes an article surveillance tag wherein the fabric material comprises an nonwoven material.

[0010] Another example aspect includes an article surveillance tag wherein the top layer and the bottom layer are fixedly attached at only three edges.

[0011] Another example aspect includes an article surveillance tag wherein the fabric material comprises a thermoplastic material, and wherein the top layer and the bottom layer are welded together at only three edges.

[0012] Another example aspect includes an article surveillance tag wherein the fabric material comprises a single sheet folded over to define the top layer and the bottom layer.

[0013] Another example aspect includes an article surveillance tag wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or a width of 4.5mm or less and a length of 80mm or greater.

[0014] Another example aspect includes an article surveillance tag wherein the induction loop is positionable at any point along the electrically conductive thread.

[0015] Another example aspect includes an article surveillance tag wherein the radio frequency identification device is positioned at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

[0016] Another example aspect includes a method for manufacturing an article surveillance tag, comprising: receiving a fabric material defining a top layer and a bottom layer, wherein the fabric material includes an electrically conductive thread interfixed, e.g., sewn or woven, into either the top layer or bottom layer of the fabric, wherein the electrically-conductive thread comprises a metal filament and a metal-coated non-metallic filament; attaching an induction loop coupled with a radio frequency identification device to the fabric material at a location overlapping the electrically conductive thread to form an antenna; positioning the top layer of the fabric material over the bottom layer of the fabric material, wherein the electrically conductive thread, theinduction loop and the radio frequency identification device are located between the top layer and bottom layer of the fabric material; and affixing the top layer of the fabric material to the bottom layer of the fabric material at a plurality of edges.

[0017] Another example aspect includes a method for manufacturing an article surveillance tag wherein the top layer and the bottom layer are fixedly attached using adhesive, sewing, or ultrasonic welding.

[0018] Another example aspect includes a method for manufacturing an article surveillance tag wherein the metal-coated non-metallic filament comprises a metal-coated non-metallic multifilament.

[0019] Another example aspect includes a method for manufacturing an article surveillance tag wherein the electrically-conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

[0020] Another example aspect includes a method for manufacturing an article surveillance tag wherein the fabric material comprises an nonwoven material.

[0021] Another example aspect includes a method for manufacturing an article surveillance tag wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or a width of 4.5mm or less and a length of 80mm or greater. For instance, dimensions are minimized to improve concealment in the garment and / or item to which the tag is attached. For example, for a tag 100 designed to fit within a seam of a garment, a maximum width may be 6.5 mm, with 2 mm being used to attach the sensor to the garment resulting in a maximum antenna width of 4.5mm. The length is determined by the desired performance, with an example of a minimum performance length being 80mm. A lower tag length is desirable for concealment.

[0022] Another example aspect includes a method for manufacturing an article surveillance tag further comprising positioning the induction loop at any point along the electrically conductive thread.

[0023] Another example aspect includes a method for manufacturing an article surveillance tag further comprising positioning the radio frequency identification device at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

[0024] A further example aspect includes method for manufacturing an article surveillance tag wherein positioning the top layer of the fabric material over the bottom layer of the fabric material comprises folding the top layer of the fabric material over the bottom layer of the fabric material.

[0025] A further example aspect includes method for manufacturing an article surveillance tag wherein the top layer and the bottom layer are fixedly attached at only three edges.

[0026] To the accomplishment of the foregoing and related ends, the one or more aspects comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative features of the one or more aspects. These features are indicative, however, of but a few of the various ways in which the principles of various aspects may be employed, and this description is intended to include all such aspects and their equivalents.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a front view of an example article surveillance tag formed with a fabric material.

[0028] Figure 2 is a front view of the article surveillance tag of Fig. 1 with the top layer of the fabric material removed to provide a view of an RFID chip coupled with an induction loop, which is coupled with an antenna integrated within the bottom layer of the fabric material.

[0029] Figures 3 is an enlarged, cross-sectional view of the article surveillance tag along line 3-3 of Figure 1.

[0030] Figure 4 is an enlarged, cross-sectional view of the article surveillance tag along line 4-4 of Figure 1.

[0031] Figure 5 is an exploded view of the article surveillance tag of Fig. 1.

[0032] Figure 6 is a perspective view of an example electrically-conductive thread interfixed, e.g., sewn or woven, into one of the top layer or the bottom layer of the fabric material, forming at least a part of the antenna of the article surveillance tag of Fig. 1.

[0033] Figure 7 is a flowchart of an example method of manufacturing the article surveillance tag of Fig. 1.

[0034] Figure 8 is a schematic diagram of an example manufacturing process for making the article surveillance tag of Fig. 1.DETAILED DESCRIPTION

[0035] Various aspects of the disclosure are now described with reference to the drawings, wherein like reference numerals are used to refer to elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to promote a thorough understanding of one or more aspects of the disclosure. It may be evident in some or all instances, however, that any aspects described below can be practiced without adopting the specific design details described below.

[0036] Aspects of the disclosure include a fabric based radio-frequency identification (RFID) article surveillance tag or label (“label” and “tag” being used interchangeably herein) and a method of making an example fabric based RFID tag.

[0037] The RFID article surveillance tag includes: a fabric material, an antenna formed from an electrically-conductive thread interfixed into the fabric material and coupled to an induction loop, and a radio frequency identification device (RFID) circuit, or microchip or chip, affixed to the induction loop. In an aspect, the fabric material includes a single fabric layer folded over and affixed at the edges to encapsulate the RFID chip and induction loop between the top and bottom layer of the fabric material. The electrically-conductive thread may include a single strand or filament, or multiple strands or filaments, which may be formed from a metal material strand / wire / filament and / or a metal-coated non-metallic strand / wire / filament. The metal material and / or metal coating may include any type of electrically-conductive metal. Further, the intefixing of the electrically-conductive thread includes being sewn into the fabric or being woven into the fabric material, and / or any type of stitching or interlacing of the electrically-conductive thread with the fabric material. The fabric-based RFID article surveillance tag with the interfixed, e.g., sewn- in or woven-in, antenna thereby forms a robust tag suitable for being attached to flexible articles of merchandise, such as apparel or garments. The RFID article surveillance tag is more flexible and softer or less rigid than prior solutions, thereby being less noticeable to a consumer wearing the article to which the tag is attached.

[0038] Referring specifically to Figs. 1-6, in one example implementation that should not be construed as limiting, the electronic article surveillance tag 100 includes a fabric material 102 onto which an antenna 104, which is formed from an electrically conductive thread 106, is affixed. The antenna 104 couples with an induction loop 108 and to which an RFID chip 110 is attached. Thus, the described configuration results in a relatively flexible electronic article surveillance tag 100, as compared to prior solutions where the tag components include structures more rigid than the fabric material 102.

[0039] The fabric material 102 includes a top layer 126 and a bottom layer 128, and the electrically conductive thread 106 of the antenna 104 may be affixed to either the top layer 126 or the bottom layer 128 (e.g., as illustrated in Figs. 2 and 5). The induction loop 108, including the RFID chip 110, may then be affixed to the electrically conductive thread 106 and / or the fabric material 102 on the respective layer 126 or 128. The induction loop may include, but it not limited to, one or more loops of an electrically-conductive material, such as a wire, in which an alternative current can induce an electric current in a nearby electrically-conductive material, such as the antenna and / or the RFID circuit. In some aspects, the top layer 126 and the bottom layer 128 of the fabric material 102 may be separate layers formed from separate sheets of material, affixed together at each edge 132. In other aspects, the top layer 126 and the bottom layer 128 of the fabric material 102 may be separate layers formed from a single sheet of material, affixed together at three edges 132 (as illustrated in the figures), such that one of edges 132 is a folded edge 130 (see Figs. 1, 3, and 4). For example, the top layer 126 of the fabric material 102 may be folded over the bottom layer 128 of the fabric material 102 to define a flexible, outer casing of the electronic article surveillance tag 100. The secured (or non-folded) edges 132 of the top layer 126 and the bottom layer 128 of the fabric material 102 respectively may be secured or affixed to one another through the use of ultrasonic welding or other attachment mechanisms such as adhesive or sewing. Further, the fabric material 102 may be any type of natural or man-made / synthetic fabric. Suitable examples of fabric material 102 include, but are not limited to, any one or any combination of cotton, wool, silk, linen, hemp, tree or plant pulp, rayon, viscose, polyester, acrylic, elastane, polypropylene, a thermoplastic material, such as plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling, and / or any type of plastic.Additionally, the fabric material 102 may have any type of weave, or may be knitted, or may be anonwoven material (made by any manufacture process, such as but not limited to a spunbound material, or a web formed / bound process).

[0040] The antenna 104 at least partially defined by the electrically conductive thread 106 interfixed, such as but not limited to being woven or sewn, into the fabric material 102 may have one or more patterns based on one or more operational characteristics of the antenna 104. For example, the pattern may be configured to provide the antenna with wireless signal transmission or wireless signal reception capabilities, as well as the ability to inductively couple with the induction loop 108. Additionally, the antenna 104 may extend across the longitudinal length of the tag 100.

[0041] In one example that should not be construed as limiting, referring specifically to Figs. 2 and 5, the antenna 104 includes a central portion 116 and opposing distal portions 112, 114 extending from each end of the central portion 116. In an aspect, the central portion 116 may be relatively straight, while the opposing distal portions 112, 114 are each defined by a plurality of arcuate shapes in a wave or sinusoidal pattern. In an example implementation, which should not be construed as limiting, the antenna 104 has a width of less than 4mm and a length of greater than 50 mm. The specified dimensions allow for high signal strength of the antenna 104 and further allow the article surveillance tag 100 to be easily hidden when affixed to the article of merchandise. It should be understood that the length and width of the antenna 104 may be variable to fit a multitude of applications where the transmission and / or reception characteristics may correspond to different, e.g., larger or smaller, dimensions.

[0042] The electrically conductive thread 106 may be a single or mono filament, or a plurality of filaments, also referred to as a multifilament. The electrically conductive thread 106 may be a solid electrically conductive material, or may have an electrically conductive material coresurrounded by a fabric material, or an electrically conductive material outer layer around a fabric material. For instance, the electrically conductive thread 106 may be a metal-coated non-metallic filament or a metal-coated non-metallic multifilament. Suitable examples of an electrically conductive material include, but are not limited to, one or any combination of copper, gold, silver, aluminum, alloys of such metals, graphite, or any other material capable of carrying an electrical signal. Suitable examples of the fabric material may be the same as those mentioned above for the fabric material 102, although the fabric material of electrically conductive thread 106 may be the same as or different from the material of fabric material 102.

[0043] In one example that should not be construed as limiting, referring specifically to Fig. 6, in the electrically conductive thread 106 may be a multifilament thread 107 including one or more non-metallic filaments twisted or combined one or more metal-coated non-metallic filaments. In this example, the multifilament thread 107 includes an electrically conductive wire component / filament 118 and one or more coated components / filaments 120, each defined by a non-metal or fabric filament 122 having an electrically conductive material coating 124. The multifilament thread 107 of this configuration allows for increased conductivity as the conductivity of the electrically conductive wire component / filament 118 combines with the conductivity provided by the extra surface area of the coated component / filament 120. The multifilament thread 107 of this configuration also has better resistance to failure, e.g., from bending or flexing, as the multifilament thread 107 can continue to function even in the event that the metal wire component / filament 118 fractures or otherwise breaks, as the signal can be conducted by the coated component / filament 120. Similarly, but conversely, if the antenna 104 is exposed to excessive amounts of heat that damages the relatively thinner electrically conductive layer of the coated component / filament 120, then the relatively thicker electrically conductive wirecomponent / filament 118 can continue to function. For instance, these features enable one of more edges 132 of the fabric material 102 to be ultrasonically welded.

[0044] The induction loop 108 has a loop shape that extends longitudinally, along a longitudinal length of the tag 100, with two spaced apart ends that define a gap 109 in the loop shape. The gap 109 may be formed at either end (as illustrated in Fig. 2 and in one of the optional locations noted in Fig. 5), or in a middle of a longitudinal side of the induction loop, e.g., the side away from overlapping with the antenna 104 (see Fig. 5). In some implementations, it may be more efficient to manufacture and design the tag 100 with the RFID chip 110, and hence the gap 109, in the middle of the long side of the induction loop 108, such as on the side opposite from where the long edge of the tag 100 is affixed together, e.g., to avoid potential damage to the RFID chip 110. In other implementations, the tag 100 may have more sensitivity with the RFID chip 110, and hence the gap 109, in the middle or a corner end of the short side or end of the induction loop 108, which can enable shorter antenna and sensor lengths, e.g., where the sensor is defined at the combination of the antenna 104, induction loop 108, and RFID chip 110. The induction loop 108 is formed of an electrically conductive material (such as one of those materials mentioned above) and is configured to inductively couple with the antenna 104. For instance, one longitudinal side of the induction loop 108 may overlap with and be affixed adjacent to the central portion 116 of the of the antenna 104. The induction loop 108 is positioned as determined by performance of the tag 100, with the location of the electrically conductive thread 106 being positioned at the edge of the induction loop 108 or between the induction loop 108 being preferred positions for better performance. The induction loop 108 may further be affixed to the fabric material 102 through an attachment mechanism such as but not limited to a first substrate layer 111, which may be a similar size as the induction loop 108, or second substrate layer 113, which may be a similar size as thetag 100. The first or second substrate layer 111 or 113 can include an adhesive layer, and / or can be formed of a material that can be affixed to, such as via sewing ultrasonic welding, to the fabric material 102. The induction loop 108 will form a magnetic field with the antenna of the corresponding tag reader, creating an electrical charge in the tag 100 which enables the RFID chip 110 to transmit a signal via the antenna 104, and the signal can be read by the tag reader. The induction loop 108 may be variable in size to accommodate a variety of applications, and, in a case where a width of the tag 100 is 4mm or less may similarly have a maximum width of 4mm.

[0045] The RFID chip 110 includes any type of integrated circuit capable for radio frequency identification communications, e.g., in combination with antenna 104 and induction loop 108. The RFID chip 110 is connected across the gap 109 in the induction loop 108, such as at an end (as illustrated in the figures) or at a longitudinal side (see Fig. 5). The location of the RFID chip 110 on the induction loop 108 may alter the properties of the antenna such as frequency and signal strength to suit a number of different applications. Further, as noted above, in some implementations, the RFID chip 110 is located at a position that is spaced apart from the edge 132 where the top and bottom layers 126, 128 of the material 102 are affixed together, e.g., to avoid being damaged during the fixation process. Also, in some cases, the RFID chip 110 may be located in the middle of the tag 100, allowing for improved protection from water infiltration.

[0046] Referring to Figs. 7 and 8, an example method 200 (Fig. 8) of making article surveillance tag 100, and an example of a manufacturing process 250 for making a plurality of article surveillance tags 100 will be described with reference to one another.

[0047] Action 202 of method 200 includes receiving a fabric material defining a top layer and a bottom layer, wherein the fabric material includes an electrically conductive thread interfixed, such as but limited to being sewn or woven, into either the top layer or bottom layer of the fabric,wherein the electrically-conductive thread comprises a metal wire and a metal-coated non-metallic filament. For example, in one implementation, action 202 includes receiving a first reel 252 of a length of the top layer 126 of the fabric material 102 and the bottom layer 128 of the fabric material 102, which could be in a single sheet (as illustrated in Fig. 8) or in separate sheets on separate reels. In any case, the electrically conductive thread 106 is woven into the fabric material 102 on either of the top layer 126 of the fabric material 102 or the bottom layer 128 of the fabric material 102. The electrically conductive thread 106 may be a single filament or multifilament, such as a multifilament including an electrically conductive wire component / filament 118 and an electrically conductive material coated component / filament 120 for increased flexibility and durability.

[0048] Action 204 of method 200 includes attaching an induction loop coupled with a radio frequency identification device to the fabric material at a location overlapping the electrically conductive thread that forms an antenna. For example, in an aspect, action 204 includes receiving a reel 254 of a length of a substrate including induction loops 108 coupled with RFID chips 110. The induction loops 108 coupled with RFID chips 110 are then affixed to the fabric material 102, for instance via an adhesive layer, ultrasonic welding, or sewing, such that the inductions loops 108 overlap the electrically conductive thread 106. The induction loop 108 may be further attached to the electrically conductive thread 106 through means such as ultrasonic welding or adhesive. In other aspects, as illustrated by line 256, the induction loops 108 coupled with RFID chips 110 may be separately attached ahead of time to the length of fabric material (e.g., by first or second substrate layer 111 or 113 (Fig. 5), including an adhesive layer, being attached to fabric material 102).

[0049] Action 206 of method 200 includes positioning the top layer of the fabric material over the bottom layer of the fabric material, wherein the electrically conductive thread, the induction loop and the radio frequency identification device are located between the top layer and bottom layer of the fabric material. For example, in an aspect, action 206 includes positioning the top layer 126 of the fabric material 102 over the bottom layer 128 of the fabric material 102, wherein the electrically conductive thread 106, the induction loop 108 and the RFID chip 110 are located between the top layer 126 and bottom layer 128 of the fabric material 102. In some aspect, this action may be accomplished by positioning separate lengths of the top layer and bottom layer of the fabric material over top of one another, either with induction loops 108 and RFID chips 110 affixed to one of the layers or with the length of the substrate containing the induction loops 108 and RFID chips 110 in between. In other aspects, this action may be accomplished by feeding the length of a single sheet of a fabric material 102, either with induction loops 108 and RFID chips 110 affixed to it or simultaneously with the length of substrate containing the induction loops 108 and RFID chips 110 (as illustrated in Fig. 8), into a folding guide 258, as illustrated at reference number 260 in Fig. 8. The folding guide 258 has a curved or C-shape that defines a channel sized less than a width of the length(s) of fabric material 102 (and substrate), resulting in the top layer 126 of the fabric material 102 being folded over the bottom layer 128 of the fabric material 102 with one folded edge 130 and three unfolded edges 132.

[0050] Action 208 of method 200 includes affixing the top layer of the fabric material to the bottom layer of the fabric material at a plurality of edges. For example, in an aspect action 208 includes affixing the top layer 126 of the fabric material 102 to the bottom layer 128 of the fabric material 102 at each edge 130, 132 or at the unfolded edges 132. This may be accomplished by feeding the layers of fabric material 102 and induction loops 108 / RFID chips 110 into an attachingmechanism 262, such as an ultrasonic welding machine, adhesive mechanism or a sewing machine. The result is a strip of a plurality of fully formed tags 100 (for clarity, Fig. 8 illustrates only a single tag 100). In an aspect, the strip of fully formed tags 100, may be fed onto a third reel 264 to transport the tags, which may be cut into individual tags at a later point in time.

[0051] One or more aspects of the disclosure may be implemented according to one or more of the following clauses.

[0052] Clause 1. An article surveillance tag, comprising: a fabric material defining a top layer and a bottom layer; an antenna comprising: an electrically-conductive thread interfixed into one of the top layer or the bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal wire and a metal-coated non-metallic filament; and an induction loop overlapping with the electrically-conductive thread, wherein the induction loop comprises metallic material; and a radio frequency identification device electrically coupled with the induction loop.

[0053] Clause 2. The article surveillance tag of clause 1, wherein the metal-coated non-metallic filament comprises a metal-coated non-metallic multifilament.

[0054] Clause 3. The article surveillance tag of any preceding clause, wherein the electrically- conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

[0055] Clause 4. The article surveillance tag of any preceding clause, wherein the fabric material comprises an nonwoven material.

[0056] Clause 5. The article surveillance tag of any preceding clause, wherein the top layer and the bottom layer are fixedly attached at only three edges.

[0057] Clause 6. The article surveillance tag of any preceding clause, wherein the fabric material comprises a thermoplastic material, and wherein the top layer and the bottom layer are ultrasonically-welded together at only three edges.

[0058] Clause 7. The article surveillance tag of any preceding clause, wherein the fabric material comprises a single sheet folded over to define the top layer and the bottom layer.

[0059] Clause 8. The article surveillance tag of any preceding clause, wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or the width being 4.5mm or less and the length being 80mm or greater.

[0060] Clause 9. The article surveillance tag of any preceding clause, wherein the induction loop is positionable at any point along the electrically-conductive thread.

[0061] Clause 10. The article surveillance tag of any preceding clause, wherein the radio frequency identification device is positioned at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

[0062] Clause 11. A method for manufacturing an article surveillance tag, comprising: receiving a fabric material defining a top layer and a bottom layer, wherein the fabric material includes an electrically-conductive thread interfixed into either the top layer or bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal wire and a metal-coated non-metallic filament; attaching an induction loop coupled with a radio frequency identification device to the fabric material at a location overlapping the electrically-conductive thread forming an antenna; positioning the top layer of the fabric material over the bottom layer of the fabric material, wherein the electrically-conductive thread, the induction loop and the radio frequency identification device are located between the top layer and the bottom layer of the fabric material;and affixing the top layer of the fabric material to the bottom layer of the fabric material at a plurality of edges.

[0063] Clause 12. The method of clause 11 , wherein the top layer and the bottom layer are fixedly attached using adhesive, sewing, or ultrasonic welding.

[0064] Clause 13. The method of any preceding clause, wherein the metal-coated non-metallic filament comprises a metal-coated non-metallic multifilament.

[0065] Clause 14. The method of any preceding clause, wherein the electrically-conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

[0066] Clause 15. The method of any preceding clause, wherein the fabric material comprises an nonwoven material.

[0067] Clause 16. The method of any preceding clause, wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or the width being 4.5mm or less and the length being 80mm or greater.

[0068] Clause 17. The method of any preceding clause, further comprising positioning the induction loop at any point along the electrically-conductive thread.

[0069] Clause 18. The method of any preceding clause, further comprising positioning the radio frequency identification device at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

[0070] Clause 19. The method of any preceding clause, wherein positioning the top layer of the fabric material over the bottom layer of the fabric material comprises folding the top layer of the fabric material over the bottom layer of the fabric material.

[0071] Clause 20. The method of any preceding clause, wherein the top layer and the bottom layer are fixedly attached at only three edges.

[0072] In general, the description of the aspects disclosed should be considered as being illustrative in all respects and not being restrictive. The scope of the present disclosure is shown by the claims rather than by the above description, and is intended to include meanings equivalent to the claims and all changes in the scope. While preferred aspects of the disclosure have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. An article surveillance tag, comprising: a fabric material defining a top layer and a bottom layer; an antenna comprising: an electrically-conductive thread interfixed into one of the top layer or the bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal filament and a metal-coated non-metallic filament; and an induction loop overlapping with the electrically-conductive thread, wherein the induction loop comprises metallic material; and a radio frequency identification device electrically coupled with the induction loop.

2. The article surveillance tag of claim 1, wherein the metal-coated non-metallic filament comprises a metal-coated non-metallic multifilament.

3. The article surveillance tag of any preceding claim, wherein the electrically- conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

4. The article surveillance tag of any preceding claim, wherein the fabric material comprises an nonwoven material.

5. The article surveillance tag of any preceding claim, wherein the top layer and the bottom layer are fixedly attached at only three edges.

6. The article surveillance tag of any preceding claim, wherein the fabric material comprises a thermoplastic material, and wherein the top layer and the bottom layer are ultrasonically-welded together at only three edges.

7. The article surveillance tag of any preceding claim, wherein the fabric material comprises a single sheet folded over to define the top layer and the bottom layer.

8. The article surveillance tag of any preceding claim, wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or the width being 4.5mm or less and the length being 80mm or greater.

9. The article surveillance tag of any preceding claim, wherein the induction loop is positionable at any point along the electrically-conductive thread.

10. The article surveillance tag of any preceding claim, wherein the radio frequency identification device is positioned at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

11. A method for manufacturing an article surveillance tag, comprising: receiving a fabric material defining a top layer and a bottom layer, wherein the fabric material includes an electrically-conductive thread interfixed into either the top layer or the bottom layer of the fabric material, wherein the electrically-conductive thread comprises a metal filament and a metal-coated non-metallic filament; attaching an induction loop coupled with a radio frequency identification device to the fabric material at a location overlapping the electrically-conductive thread forming an antenna; positioning the top layer of the fabric material over the bottom layer of the fabric material, wherein the electrically-conductive thread, the induction loop and the radio frequency identification device are located between the top layer and the bottom layer of the fabric material; and affixing the top layer of the fabric material to the bottom layer of the fabric material at a plurality of edges.

12. The method of claim 11, wherein the top layer and the bottom layer are fixedly attached using adhesive, sewing, or ultrasonic welding.

13. The method of any preceding claim, wherein the metal-coated non-metallic filament comprises a metal-coated non-metallic multifilament.

14. The method of any preceding claim, wherein the electrically-conductive thread comprises a central portion and opposing distal portions on each end of the central portion, wherein the opposing distal portions each comprise a plurality of arcuate shapes, and wherein the induction loop overlaps the central portion.

15. The method of any preceding claim, wherein the fabric material comprises an nonwoven material.

16. The method of any preceding claim, wherein the antenna has a width of less than 4mm and a length of greater than 50mm, or the width being 4.5mm or less and the length being 80mm or greater.

17. The method of any preceding claim, further comprising positioning the induction loop at any point along the electrically-conductive thread.

18. The method of any preceding claim, further comprising positioning the radio frequency identification device at a longitudinal end of the induction loop, or at a middle of a side of the induction loop.

19. The method of any preceding claim, wherein positioning the top layer of the fabric material over the bottom layer of the fabric material comprises folding the top layer of the fabric material over the bottom layer of the fabric material.

20. The method of any preceding claim, wherein affixing the top layer of the fabric material to the bottom layer of the fabric material comprises fixedly attaching at only three edges.

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