Lasered fabric device

Abstract

The present invention relates to a method for fabricating a fabric RF component (101), the method comprising: providing a combined structure (102) comprising a conductive fabric layer (120) fixedly attached on a dielectric substrate (125), the conductive fabric layer (120) comprises a first area (301) and a second area (302); and producing with a laser beam (402) an ablation pattern (505) with a varying pattern density on the first area (301) of the conductive fabric layer (120) to form a non-conductive part (320) of the fabric RF component (101) so that the pattern density of the ablation pattern (505) is greater at a selected part (335) of the first area (301) than other parts of the first area (301), wherein the second area (302) of the conductive fabric layer without the ablation pattern forms the conductive part (321) of the fabric RF component (101).

Description

[0001] LASERED FABRIC DEVICE

[0002] Field of the invention

[0003] The present invention relates to a method for fabricating a fabric RF component, the method comprising at least providing a combined structure comprising a conductive fabric layer fixedly attached on a dielectric substrate, the conductive fabric layer comprises a first area and a second area; and producing with a laser beam an ablation pattern with a varying pattern density on the first area of the conductive fabric layer to form a non-conductive part of the fabric RF component so that the pattern density of the ablation pattern is greater at a selected part of the first area than other parts of the first area, wherein the second area of the conductive fabric layer without the ablation pattern forms the conductive part of the fabric RF component.

[0004] The invention also relates to a fabric RF component, i.e. a lasered fabric device, that is produced by the method according to the present invention, and to a wireless communication device that is configured to exchange wireless signals via the fabric RF component.

[0005] The present invention relates generally to the field of fabric-based radio frequency (RF) components. More particularly, it concerns laser-based methods for selectively ablating conductive textiles so as to form a desired radiating antenna structure or RF circuit pattern, as well as the resulting fabric RF component and devices integrating such components.

[0006] The present invention relates particularly to methods of high-speed, pulsed laser ablation in the manufacturing of textile antennas from conductive fabric laminates. The invention further relates to planar and layered fabric RF products and their integration into shells or rigidized bodies (e.g., vehicle body panels).

[0007] Background of the invention

[0008] In recent years, textile antennas and other flexible RF structures have gained popularity for use in wearable devices, conformal sensors, and vehicular or aerospace applications where low weight and structural integration are paramount. Traditional processes for patterning conductive textiles — such as mechanical cutting, chemical etching, or screen printing - often lack thethroughput and precision needed to rapidly customize antenna designs or to mass-produce accurately dimensioned RF layers.

[0009] Laser processing, by contrast, offers a non-contact means of selectively removing conductive material from a laminated substrate-conductor stack. In particular, pulsed laser ablation makes it possible to achieve fine resolution and localized material removal without significant damage to the underlying dielectric. When such laser ablation is performed using galvanometer mirror systems, in contrast to traditional CO2-based fabric cutting lasers, the beam can be rapidly redirected across the fabric surface, eliminating the need for physically moving either the fabric or the laser head. This allows roll-to-roll or similarly continuous production schemes to operate at high speeds, significantly increasing throughput.

[0010] With specifically configured laser beam parameters, the conductive fabric can be ablated from a laminated stack of a conductive / non-conductive substrate “raw material” without cutting through the underlying non-conductive fabric. This approach allows a novel combination of accurate and fast laser-produced fabric patterning with more traditional textile industry assembly methods such as sewing. The presented antenna topology utilizes modulated surface impedance of the substrate, on the basis of a plurality of conductive patches that are dimensioned to remain as a fixed part of the laminate, and leaved on the substrate surface to operate as a part of the fabric RF components, thus removing the need to detach or remove the non-conductive (non-conductive to DC current) areas of the RF components.

[0011] The disclosed invention harnesses these laser fabrication advantages to create advanced antenna topologies. By controlling the pattern density of ablated lines or hatches, one can finely tune the electromagnetic properties of the textile layer - such as surface impedance, capacitive loading, or frequency-selective behavior. These enhancements are particularly useful for designing planar and layered fabric RF products, including fabric antennas capable of forming or being embedded in shells, such as clothing layers, automotive interior panels, vehicle body covers with resin reinforcement, or other rigidized structural elements.

[0012] Harnessing the fabric RF component of the present invention for wireless communication enables highly integrated, low-profile devices that are well-suited for loT, vehicle-to-vehicle (V2V), or wearable applications. This approach also affords easier device miniaturization and improved portability or aesthetics when compared to traditional bulky metal antennas that protrude from housings or garments.

[0013] The invention advances the state of the art by seamlessly merging the antenna structure into textile or composite layers, providing soft or rigid shells with embedded RF functionality. This novel approach is especially relevant for smart textiles, industrial loT, UAV communications, and connected vehicles, where combining mechanical functionality, wearability, and antenna performance in a single solution yields significant innovation and commercial potential.

[0014] Brief summary of the invention

[0015] The following presents a simplified summary in order to provide basic understanding of some aspects of various invention embodiments. The summary is not an extensive overview of the invention. It is neither intended to identify key or critical elements of the invention nor to delineate the scope of the invention. The following summary merely presents some concepts of the invention in a simplified form as a prelude to a more detailed description of exemplifying embodiments of the invention.

[0016] It is an aim of the present invention to improve upon the state of the art by providing a method to rapidly and selectively remove conductive material from a laminated substrate-conductor stack using pulsed laser ablation guided by a galvanometer-based beam steering system. The invention enables quick customization of textile antennas in high-volume production lines - such as roll-to-roll processing - while maintaining precise dimensional control and minimizing substrate damage.

[0017] By carefully adjusting the pattern density of ablation, the resulting antenna structures feature localized impedance and capacitance tuning, thereby enhancing or expanding their RF performance capabilities.

[0018] The aim is also to provide a fast, scalable, and versatile solution that seamlessly integrates fabric RF components into shells (e.g., clothing, cushions, protective gear) or rigidized bodies (e.g., automotive panels, UAV fuselages) without the need for complex mechanical fixtures or costly tooling.This invention therefore optimizes both the design freedom and the manufacturing throughput of textile antennas, benefiting wearable electronics, vehicle communication systems, and various commercial or industrial applications where lightweight and integrated antenna solutions are essential. The objectives of the invention are reached by a method and a fabric RF component as defined by the respective independent claims.

[0019] Various exemplifying and non-limiting embodiments of the invention both as to constructions and to methods of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific exemplifying and non-limiting embodiments when read in connection with the accompanying drawings.

[0020] The verbs “to comprise” and “to include” are used in this document as open limitations that neither exclude nor require the existence of unrecited features. The features recited in dependent claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of “a” or “an”, i.e. a singular form, throughout this document does not exclude a plurality.

[0021] Description of the drawings

[0022] In the following, the present invention will be described in more detail with reference to the appended drawings, in which

[0023] Figure 1 shows a fabric RF component, in accordance with an embodiment; Figure 2 presents a side view of a product incorporating the fabric RF component according to the present invention;

[0024] Figure 3 provides a schematic illustration of a wireless communication device that exchanges wireless signals using the fabric RF component, in accordance with an embodiment.

[0025] Detailed description of the invention

[0026] The detailed description of the present invention presents various characteristics of the present invention. The examples at the end of thespecification describe the embodiments to reach the technical advantages of the provided characteristics.

[0027] In accordance with an embodiment, there is provided a method for fabricating a fabric RF component 101, the method comprising: providing a combined structure 102 comprising a conductive fabric layer 120 fixedly attached on a dielectric substrate 125, the conductive fabric layer 120 comprises a first area 301 and a second area 302; and producing with a laser beam 402 an ablation pattern 505 with a varying pattern density on the first area 301 of the conductive fabric layer 120 to form a non-conductive part 320 of the fabric RF component 101 so that the pattern density of the ablation pattern 505 is greater at a selected part 335 of the first area 301 than other parts of the first area 301 , wherein the second area 302 of the conductive fabric layer without the ablation pattern forms the conductive part 321 of the fabric RF component 101.

[0028] The embodiment sets forth a method for fabricating a fabric RF component that leverages laser-based ablation to create a non-conductive part in a specified region of a conductive textile. This approach yields several key advantages in terms of processing speed, integration of advanced RF components, and design freedom for antenna topologies, as outlined below: By using a laser beam to produce an ablation pattern in the first area of the conductive fabric layer, the invention allows high-speed material removal. Traditional methods, such as chemical etching or mechanical cutting, either require lengthy chemical processes or physically move cutting tools across the substrate. In contrast, laser ablation - especially with a high repetition-rate pulsed beam - can be performed rapidly and digitally. Consequently, manufacturers benefit from reduced processing time compared to manual cutting, stamping, or chemical etching, non-contact operation that minimizes wear on tools, roll-to-roll production compatibility, enabling large volumes of fabric to be processed continuously with minimal setup changes.

[0029] The ablated pattern with varying density provides a new dimension of controllability over the electromagnetic properties of the final textile antenna or RF structure. Rather than uniformly removing entire regions, the method localizes removal to selected parts, allowing the remainder of the second area to remain fully conductive, and leaving the small isolated patches of theconductive material attached as a part of the antenna element, but with minimal performance deteriorating effect. This leads to precise tuning of surface impedance, capacitance, or other RF parameters in localized regions, Integration of complex impedance-matching networks, frequency-selective surfaces, or edge loading directly onto standard textile materials, preservation of the physical properties (flexibility, drape) of the underlying fabric, enabling wearable, conformal, or structural fabric-based antennas.

[0030] The selected part can serve as an area of capacitively loaded or impedance-modulated material, refining antenna performance (e.g., bandwidth broadening, miniaturization, or multi-band operation). It becomes feasible to form or enhance a frequency selective surface, effectively controlling how the antenna couples with external signals at one or more frequencies.

[0031] Figure 1 illustrates a top view of one possible layout of such a fabric RF component 101. As shown in Fig. 1, the combined structure 102 may be formed as a substantially planar laminate, wherein:

[0032] - Conductive fabric layer 120

[0033] This is the electrically conductive layer applied to the top surface of the dielectric substrate 125. It is divided into at least two main regions: the first area 301 , which will be subjected to laser ablation, and the second area 302, which is left intact and forms the primary conductive portion of the antenna or RF structure.

[0034] - Dielectric substrate 125

[0035] This substrate is bonded to or underlies the conductive fabric layer 120, providing mechanical support and an insulating medium. The laser ablation removes the conductive layer only down to (but not through) the surface of this substrate, preserving its integrity.

[0036] In an embodiment, the combined structure 102 may be a laminate comprising the conductive fabric layer 120 and a dielectric substrate 125 fixedly adhered together.

[0037] In an embodiment, the combined structure 102 may be provided in a roll of a laminate comprising the conductive fabric layer 120 and a dielectric substrate 125 fixedly adhered together.In an embodiment of the method, the combined structure 102 may be provided as a roll comprising the conductive fabric layer 120 and a dielectric substrate 125 fixedly adhered together.

[0038] - First area 301

[0039] A portion of the conductive layer 120 designated for partial or complete removal via the ablation pattern 505. Within this first area 301, the ablation lines 504 are created by the laser beam 402, forming the non-conductive part 320 where the conductive material has been removed. The non-conductive part 320 comprises a plurality of electrically isolated patches of the conductive fabric layer 120 that remain fixedly attached to the substrate after the selective laser ablation.

[0040] - Second area 302

[0041] The region of the conductive layer 120 where no ablation pattern is applied, or which may be framed with the ablation pattern 505. In another embodiment, the second area 302 may be framed with a frequency selective surface 302. This second area 302 remains electrically continuous at a first frequency of a microwave signal, and serves as the conductive part 321 of the final fabric RF component 101 (for example, forming a radiating patch, ground plane, or feed element).

[0042] - Non-conductive part 320

[0043] Created in the first area 301 after the ablation pattern 505 is formed. This part no longer conducts due to the conductive material having been selectively removed. This non-conductive area 320 is electrically non-continuous at a first frequency of a microwave signal, or at a DC current, due to plurality of electrically isolated patches of the conductive fabric layer 120 that remain fixedly attached to the substrate after the selective laser ablation, but are isolated from adjacent patches due to the selective laser removal.

[0044] - Conductive part 321

[0045] The electrically active region of the conductive layer 120 that retains its metallic properties. It may include an antenna patch, feed line, or other intended RF structure.- Laser beam 402

[0046] The pulsed laser light directed by a galvanometer system (not separately shown) to trace the lines 504, thus generating the ablation pattern 505. Because the galvanometer steering does not require physical movement of the substrate or the laser head, high-speed production and precise patterning may be achieved.

[0047] - Galvanometer 420

[0048] A precision electromechanical device that uses one or more rapidly adjustable mirrors 422 to steer the laser beam 402 across a marking field 410. By controlling the angular position of the galvanometer 420, the system can ablate the conductive layer 120 in precise patterns with high speed and accuracy. - Marking field 410

[0049] This refers to the defined processing area or “scan area” in which the laser beam 402 can be freely deflected and positioned by the galvanometer 420. In other words, the marking field 410 delimits the zone on the substrate where the laser ablation pattern 505 is to be formed, without having to physically move the combined structure 102 or the laser head.

[0050] - Mirror 422

[0051] One of potentially multiple reflective elements used to deflect and guide the laser beam 402 within the galvanometer 420. The mirror 422 (often coupled with another orthogonal mirror) enables the beam to scan in both x and y directions within the marking field 410, thus producing the desired pattern of ablation lines 504 in the first area 301 with fast throughput.

[0052] - Ablation lines 504

[0053] Fine grooves or channels formed where the laser beam 402 removes the conductive layer 120 along predefined paths. A group, an array, or a plurality of overlaps of these lines 504 constitutes the overall ablation pattern 505.

[0054] - Ablation pattern 505

[0055] The collective result of the ablation lines 504 in the first area 301. Its density (i.e. , how closely spaced or overlapping the lines are) determines how fully theconductive material is removed and thus the electrical or capacitive effect each region contributes.

[0056] - Selected part 335

[0057] A region within the first area 301 where the ablation pattern 505 is intentionally made denser (or otherwise patterned differently) to achieve a particular electrical effect, such as increased capacitive loading or altered surface impedance.

[0058] - Edge region 610

[0059] In this illustrative example, certain sections labeled 610 show where the non-conductive part 320 and the conductive part 321 meet. These edge regions can be hatched more densely to modulate the antenna’s impedance or to provide frequency-selective behavior. In an embodiment, the method may comprise producing with a laser beam 402 an ablation pattern 505, in which the edge regions 610 may be configured to load the electric fields emitted from a first 205 or a second 206 radiating edge.

[0060] - First set of isolated conductive regions 465

[0061] Characteristic of the ablation pattern 505 that results in discrete or “isolated” conductive segments within the first area 301.

[0062] - Second set of isolated conductive regions 466

[0063] Another group of discrete conductive segments formed by the laser ablation, typically distinct or separated from the first set of isolated conductive regions 465. By creating multiple isolated regions (465 and 466) in different patterns or densities, the final fabric RF component 101 can exhibit more complex electromagnetic characteristics, such as multi-band operation or tailored surface impedance distributions.

[0064] The pattern density of ablation can be adjusted so that the conductive material is partly or completely removed in desired sections. This selective removal allows for precise tuning of the antenna or RF component’s resonance, impedance, or bandwidth. Fig. 1 demonstrates one exemplary configuration, but various shapes and distributions of ablation lines 504 may be employed to produce different RF characteristics in the final fabric RF component 101.Figure 2 presents a side view of a layered device incorporating the fabric RF component 101. With respect to Fig.2, the radiating layer 710 indicates the functional antenna or RF-emitting portion of the structure - namely, the portion of the conductive layer 120 that remains intact (or partially patterned) to serve as the actual radiating element. In many embodiments, the radiating layer 710 corresponds to the conductive part 321 or to a specialized region within that conductive part.

[0065] The layered compound 712 may refer to the entire multi-layer assembly beneath or above the combined structure 102. The layered compound 712 may include the dielectric substrate 125, any additional adhesive or protective layers (part of the combined structure 102), and the conductive fabric layer 120 itself. This compound can be further integrated or laminated into a garment shell, a protective panel, or other end-use applications. As shown, the ablation lines 504 penetrate only through the conductive fabric layer 120 (down to the surface of substrate 125), thereby preserving the structural integrity of the layered compound 712 while forming the desired antenna topology in the radiating layer 710.

[0066] In accordance with an embodiment the selected part 335 of the first area 301 may comprise an edge region 610 next to the conductive part 321 of the fabric RF component 101.

[0067] The selected part 335 of the first area 301 may comprise an edge region 610 next to the conductive part 321 of the fabric RF component 101. This approach is particularly advantageous for antenna design, as edges are often the location of peak fringing fields or high-voltage boundaries in patch and microstrip antennas. By applying a denser ablation pattern or otherwise modulating the fabric’s conductivity specifically at the edge region 610, one can effectively tune the antenna’s impedance, expand its bandwidth, or introduce capacitive loading without altering the entire patch geometry. This selective focus on the edge region thus provides finer control over resonance and possibly a miniaturization of the antenna element.

[0068] The producing the ablation pattern 505 may comprise selectively removing with the laser beam 402 the conductive fabric layer 120 at lines 504 forming the ablation pattern 505.Defining the ablation as a series of lines offers several benefits: it allows for precise, repeatable patterning using digital control of the laser path, and it ensures uniform and clean removal of the conductive layer along tightly defined contours. Such line-based ablation is critical for complex designs (e.g., frequency-selective surfaces or multi-band antennas) where sharp transitions between conductive and non-conductive regions must be maintained.

[0069] The laser beam 402 may be a pulsed beam with a pulse repetition frequency exceeding 10 kHz, and in forming the ablation pattern 505, selectively removing said conductive layer 120 at said lines 504 from a first surface of said conductive layer 120 to a surface of the dielectric substrate 125 that is fixedly attached to said conductive layer may be comprised, and without cutting through the opposite surface of said dielectric substrate 125 under said lines 504.

[0070] By using a high-frequency pulsed laser, preferably an infrared laser that is advantageously absorbed by metallic surfaces of textile fibers, the process achieves rapid material removal while keeping heat-affected zones minimal. This protects the substrate and maintains overall mechanical integrity. Moreover, the high repetition rate enables faster scanning speeds, thereby increasing throughput in mass production and ensuring the ablation lines do not inadvertently penetrate or weaken the dielectric layer.

[0071] In an embodiment, the pulse duration of the laser beam may be configured between 1 ns and 500 ns.

[0072] In another embodiment, the pulse duration of the laser beam may be configured between 1 ps and 1 ns.

[0073] In the method of the present invention, the producing the ablation pattern 505 may comprise providing the combined structure 102 in a marking field 410 of a galvanometer 420 that is configured to deflect said laser beam 402 by means of at least two mirrors 422, and using a computerized model of said lines 504 for forming said ablation pattern 505 on the basis of the movement of said at least two mirrors 422.

[0074] This provides several key advantages, such as high speed: The galvanometer’s mirrors can rapidly redirect the beam across the marking field, enabling fast and continuous ablation over large fabric areas. Secondly, thereis no mechanical translation required: Neither the laser head nor the substrate must physically move, reducing mechanical complexity and preserving registration accuracy. Third, a flexible digital control allows the entire ablation pattern updated in a computerized model. Adjustments can be made on-the-fly, allowing customizable or complex geometries to be implemented without retooling.

[0075] In accordance with the method of the present invention, the producing the ablation pattern 505 may comprise modulating the surface impedance of the surface of the dielectric substrate 125 within the selected part 335 by the capacitance over the ablation pattern 505 within said selected part 335.

[0076] By deliberately leaving behind small conductive segments or patterns, one alters the local E-field distribution at the substrate’s top interface. This change in surface impedance (the ratio of tangential E to tangential H) can be used to tune antenna resonances, reduce the overall size of the antenna (miniaturization), suppress surface waves, or broaden its operational bandwidth. The locally increased capacitance may be configured to effectively load the antenna structure, thereby lowering the resonant frequency for the same physical area or enabling narrowband vs. wideband operational adjustments.

[0077] In accordance with the method of the present invention, the producing the ablation pattern 505 may comprise hatching the edge region 610 with said ablation pattern 505 to increase the effective permittivity of the dielectric substrate 125 under the selected part 335 by the capacitance of the conductive fabric layer 120 through the dielectric substrate 125.

[0078] Edge regions where the surface current is minimal, are typically where tangential E-fields fringe most strongly in patch antennas. The direct vicinity of these edges are typically the most sensitive regions for the antenna operational frequency to be affected by, with negative or positive effects. By hatching or creating a denser ablation pattern near these edges, additional capacitive coupling occurs between remaining conductive islands and the underlying substrate. This locally raises the effective dielectric constant (“permittivity”) in that zone, influencing how electric field energy is stored in the near-field. As a result, one may shift resonance or reduce the antenna’sfootprint without sacrificing performance, because the antenna may effectively experience a “larger” reactive environment.

[0079] In accordance with the method of the present invention, the producing the ablation pattern 505 may comprise forming the conductive part 321 as an antenna having at least a first radiating edge 205 and a second radiating edge 206 at a first frequency, and separating said first radiating edge 205, from the first area 301 using the ablation pattern 505 of the edge region 610, and loading the first radiating edge 205 with the capacitance of the selected part 335.

[0080] By selectively placing the ablation pattern in the edge region and retaining small areas of conductive material near the radiating edges, one can intentionally load the antenna. The added capacitance at this boundary modifies the E-field distribution along the radiating edge 205, while allowing the antenna near fields to radiate away from the structure without remaining stored in the non-radiating fields.

[0081] In accordance with the method of the present invention, the producing the ablation pattern 505 may comprise extending the selected part 335 over the other parts of the first area 301 as a frequency selective surface 312, wherein the frequency selective surface 312 has a passband at the first frequency, and framing the second area 302 with said frequency selective surface.

[0082] A frequency selective surface (FSS) is created when the ablation pattern forms a repeated or carefully dimensioned arrangement of conductive segments (or slots) tuned to pass or reflect specific frequencies. By “framing” the conductive area (the main patch or radiator) with an FSS, it is possible to enhance or suppress certain modes, boost bandwidth, or isolate the antenna from undesired external signals. This approach is especially beneficial for multiband or high-selectivity applications, since it allows the substrate and conductive pattern itself to handle frequency filtering instead of requiring extra bulky components. Furthermore, when the remnant conductive patches are left fixedly attached after the selective laser removal, the process remains fast, and removes all material waste.

[0083] Advantageous conductive layer’s thread density (>100 threads / dm) in two directions imparts structural integrity and durability to the fabric, making it suitable for repeated bending, flexing, or vibration without fraying ordelamination. This robustness is particularly important for antenna structures that may be installed, worn, or subjected to environmental stresses across a wide frequency range (e.g. from 10 MHz to 100 GHz).

[0084] A sheet resistance of less than 100 Q / square ensures low RF losses, enables efficient radiation or signal transfer, even at higher frequencies approaching millimeter-wave bands. The dense cross-thread configuration creates a more uniform conductive surface, supporting stable performance for both broadband and narrowband antenna designs.

[0085] In accordance with an embodiment, the method according to the present invention may comprise: providing the combined structure 102 comprising a conductive fabric layer 120 with a sheet resistance less than 100 Q / square, wherein said conductive fabric layer 120 comprises at least 100 threads / dm thread density of electrically conductive threads in two crossing directions, and; using a combination of pulse repeating frequency and ablation speed that result in the selective removal of the conductive fabric layer at said lines 504 for forming the ablation pattern 505, and; providing the selected part 335 with a first set of isolated conductive regions 465 having an area between 0.25-25 mm2, and the other parts with a second set of isolated conductive regions 466 having an area between 1-250 mm2 such that the area of said second area 302 is at least 4 times as large as the isolated conductive regions of the selected part 335, wherein; forming said ablation pattern 505 to form said first 465 and second 466 set of isolated conductive regions.

[0086] Providing the selected part 335 with a first set of isolated conductive regions 465 having an area between 0.25-25 mm2 can be particularly effective in enhanced reliability of the process; There remains a possibility that some of the laser-ablated yarns remain uncut, and short circuits may remain. This kind of process would deteriorate the end product. Therefore, by concentrating the dense patterning with small isolated conductive regions into areas of critical importance, the reliability of the process is enhanced. The larger isolated conductive regions may be positioned further away from these areas of critical importance, thus increasing the production speed, and creating a smaller negative impact on antenna radiation efficiency.

[0087] When the area of said second area 302 is at least 4 times as large as the isolated conductive regions of the selected part 335, the resonances of theisolated regions within the selected part 335 do not interfere with the resonance frequency of the second area 302, which is advantageously configured as a fabric antenna.

[0088] For instance, smaller regions can act as parasitic or loading elements at higher frequencies, while larger regions handle lower frequency energy. This modular approach accommodates broad operating ranges (10 MHz to 100 GHz) by tailoring local fields in each region.

[0089] Figure 3 provides a schematic illustration of a wireless communication device that exchanges wireless signals 715 using the fabric RF component 101, according to an embodiment. The example shows how the radiating layer 710, integrated into a layered compound 712, may form a part of a device capable of transmitting or receiving signals, for example to and from a remote server (cloud) or any suitable communication network node.

[0090] By embedding the conductive textile in a multi-layer assembly, designers can leverage conformal shapes, improved aerodynamic or ergonomic properties, and enhanced protection (e.g., in helmets or vehicle panels) without compromising antenna performance.

[0091] In practical applications, the wireless communication device may be implemented in various real-life scenarios, such as:

[0092] - Wearable Electronics: The fabric RF component 101 can be embedded in smart garments or protective clothing, allowing real-time body monitoring or continuous wireless communication, according to an embodiment.

[0093] - Automotive or Aerospace Systems: The layered compound 712 and radiating layer 710 may be integrated into vehicle body panels, interior linings, or drone fuselages, providing embedded antennas for telematics or telemetry, according to the present invention.

[0094] - Furniture or Cushioning: Seats, cushions, or upholstery may incorporate the fabric RF component 101 to enable contactless sensing, occupancy detection, or Bluetooth / Wi-Fi connectivity, according to an embodiment. - Consumer Devices: Luggage, backpacks, and other accessories may include the layered compound 712 for RFID or loT tagging, with soft and conformal antenna according to an embodiment.- Industrial or Infrastructure Equipment: The radiating layer 710 may be part of enclosures or housings where it serves as a robust, low-profile antenna for sensor networks, wireless controls, or remote machine communications, according to an embodiment.

[0095] In accordance with an embodiment, the RF component 101 may be configured as a radiating layer 710 of a layered compound 712, wherein said compound 712 forms a shell of a clothing, helmet, sail, cushioning, upholstery, thermal insulator, footwear, automotive interior, automotive body, fuselage, drone.

[0096] In accordance with an embodiment, there may be provided a wireless communication device wherein the wireless communication device is configured to exchange wireless signals 715 via the fabric RF component 101 according to any of the preceding examples.

[0097] In the following some examples of the embodiments according to the present invention will be provided.

[0098] In accordance with a first example, there is provided a method for fabricating a fabric RF component 101, the method comprising: providing a combined structure 102 comprising a conductive fabric layer 120 fixedly attached on a dielectric substrate 125, the conductive fabric layer 120 comprises a first area 301 and a second area 302; and producing with a laser beam 402 an ablation pattern 505 with a varying pattern density on the first area 301 of the conductive fabric layer 120 to form a non-conductive part 320 of the fabric RF component 101 so that the pattern density of the ablation pattern 505 is greater at a selected part 335 of the first area 301 than other parts of the first area 301 , wherein the second area 302 of the conductive fabric layer without the ablation pattern forms the conductive part 321 of the fabric RF component 101.

[0099] In accordance with a second example, the selected part 335 of the first area 301 may comprise an edge region 610 next to the conductive part 321 of the fabric RF component 101.

[0100] In accordance with a third example, the producing the ablation pattern 505 may comprise selectively removing with the laser beam 402 the conductive fabric layer 120 at lines 504 forming the ablation pattern 505.

[0101] In accordance with a fourth example, the laser beam 402 may be a pulsed beam with a pulse repetition frequency exceeding 10 kHz, and in forming theablation pattern 505, selectively removing said conductive layer 120 at said lines 504 from a first surface of said conductive layer 120 to a surface of the dielectric substrate 125 that is fixedly attached to said conductive layer may be comprised, and without cutting through the opposite surface of said dielectric substrate 125 under said lines 504.

[0102] In accordance with a fifth example, the producing the ablation pattern 505 may comprise providing the combined structure 102 in a marking field 410 of a galvanometer 420 that is configured to deflect said laser beam 402 by means of at least two mirrors 422, and using a computerized model of said lines 504 for forming said ablation pattern 505 on the basis of the movement of said at least two mirrors 422.

[0103] In accordance with a sixth example, the producing the ablation pattern 505 may comprise modulating the surface impedance of the surface of the dielectric substrate 125 within the selected part 335 by the capacitance over the ablation pattern 505 within said selected part 335.

[0104] In accordance with a seventh example, the producing the ablation pattern 505 may comprise hatching the edge region 610 with said ablation pattern 505 to increase the effective permittivity of the dielectric substrate 125 under the selected part 335 by the capacitance of the conductive fabric layer 120 through the dielectric substrate 125.

[0105] In accordance with a eight example, the producing the ablation pattern 505 may comprise forming the conductive part 321 as an antenna having at least a first radiating edge 205 and a second radiating edge 206 at a first frequency, and separating said first radiating edge 205, from the first area 301 using the ablation pattern 505 of the edge region 610, and loading the first radiating edge 205 with the capacitance of the selected part 335.

[0106] In accordance with a ninth example, the producing the ablation pattern 505 may comprise extending the selected part 335 over the other parts of the first area 301 as a frequency selective surface 312, wherein the frequency selective surface 312 has a passband at the first frequency, and framing the second area 302 with said frequency selective surface.

[0107] In accordance with a tenth example, the method according to the present invention may comprise: providing the combined structure 102 comprising aconductive fabric layer 120 with a sheet resistance less than 100 Q / square, wherein said conductive fabric layer 120 comprises at least 100 threads / dm thread density of electrically conductive threads in two crossing directions, and; using a combination of pulse repeating frequency and ablation speed that result in the selective removal of the conductive fabric layer at said lines 504 for forming the ablation pattern 505, and; providing the selected part 335 with a first set of isolated conductive regions 465 having an area between 0.25-25 mm2, and the other parts with a second set of isolated conductive regions 466 having an area between 1-250 mm2 such that the area of said second area 302 is at least 4 times as large as the isolated conductive regions of the selected part 335, wherein; forming said ablation pattern 505 to form said first 465 and second 466 set of isolated conductive regions.

[0108] In accordance with a eleventh example, there is provided a fabric RF component 101, wherein the fabric RF component 101 may comprise: a combined structure 102 comprising a conductive fabric layer 120 fixedly attached on a dielectric substrate 125, wherein the conductive fabric layer 120 comprises a first area 301 and a second area 302; and an ablation pattern 505 produced with a laser beam 402 with a varying pattern density on the first area 301 of the conductive fabric layer 120 that is configured to form a non-conductive part 320 of the fabric RF component 101 so that the pattern density of the ablation pattern 505 is greater at a selected part 335 of the first area 301 than other parts of the first area 301, wherein the second area 302 of the conductive fabric layer without the ablation pattern forms the conductive part 321 of the fabric RF component 101.

[0109] In accordance with a twelfth example, there is provided the fabric RF component 101, wherein; the ablation pattern 505 may be formed with selectively removed lines 504 from a first surface of said conductive layer 120 to a surface of the dielectric substrate 125 that is fixedly attached to said conductive layer, and without being cut through the opposite surface of said dielectric substrate 125 under said lines 504, and wherein said lines may be cut with a line width of 10-200 urn on the conductive fabric layer 120 wherein the sheet resistance of said conductive fabric layer may be less than 100 Q / square, wherein said conductive fabric layer 120 may comprise at least 100 threads / dm thread density of electrically conductive threads in two crossing directions, and; wherein the selected part 335 may comprise a first set of isolated conductive regions 465 having an area between 0.25-25 mm2, andthe other parts of the first area 301, may comprise a second set of isolated conductive regions 466 having an area between 1-250 mm2 wherein the area of said second area 302 is at least 4 times as large as the isolated conductive regions of the selected part 335, wherein; said ablation pattern 505 may form said first 465 and second 466 set of isolated conductive regions with a plurality of crossing lines 504.

[0110] In accordance with a thirteenth example, the fabric RF component 101 the fabric RF component 101 may be produced by the method according to the present invention.

[0111] In accordance with a fourteenth example, the RF component 101 may be configured as a radiating layer 710 of a layered compound 712, wherein said compound 712 forms a shell of a clothing, helmet, sail, cushioning, upholstery, thermal insulator, footwear, automotive interior, automotive body, fuselage, or drone.

[0112] In accordance with a fifteenth example, there is provided a wireless communication device comprising the fabric RF component 101 according to any of the preceding examples, wherein the wireless communication device is configured to exchange wireless signals 715 via the fabric RF component 101. The present invention is not limited solely to the above-presented embodiments, but it can be modified within the scope of the appended claims.

Claims

CLAIMS1. A method for fabricating a fabric RF component (101), the method comprising:- providing a combined structure (102) comprising a conductive fabric layer (120) fixedly attached on a dielectric substrate (125), the conductive fabric layer (120) comprises a first area (301) and a second area (302); and- producing with a laser beam (402) an ablation pattern (505) with a varying pattern density on the first area (301 ) of the conductive fabric layer (120) to form a non-conductive part (320) of the fabric RF component (101) so that the pattern density of the ablation pattern (505) is greater at a selected part (335) of the first area (301) than other parts of the first area (301), wherein the second area (302) of the conductive fabric layer without the ablation pattern forms the conductive part (321) of the fabric RF component (101 ).

2. The method according to claim 1 , wherein the selected part (335) of the first area (301) comprises an edge region (610) next to the conductive part (321) of the fabric RF component (101).

3. The method according to any of the preceding claims, wherein the producing the ablation pattern (505) comprises selectively removing with the laser beam (402) the conductive fabric layer (120) at lines (504) forming the ablation pattern (505).

4. The method according to claim 3, wherein the laser beam (402) is a pulsed beam with a pulse repetition frequency exceeding 10 kHz, and in forming the ablation pattern (505), selectively removing said conductive layer (120) at said lines (504) from a first surface of said conductive layer (120) to a surface of the dielectric substrate (125) that is fixedly attached to said conductive layer, and without cutting through the opposite surface of said dielectric substrate (125) under said lines (504).

5. The method according to claim 3 or 4, wherein the producing the ablation pattern (505) comprises providing the combined structure (102) in a marking field (410) of a galvanometer (420) that is configured to deflect said laser beam(402) by means of at least two mirrors (422), and using a computerized model of said lines (504) for forming said ablation pattern (505) on the basis of the movement of said at least two mirrors (422).

6. The method according to any of the claims 3-5, wherein the producing the ablation pattern (505) comprises modulating the surface impedance of the surface of the dielectric substrate (125) within the selected part (335) by the capacitance over the ablation pattern (505) within said selected part (335).

7. The method according to any of the claims 3-5, wherein the producing the ablation pattern (505) comprises hatching the edge region (610) with said ablation pattern (505) to increase the effective permittivity of the dielectric substrate (125) under the selected part (335) by the capacitance of the conductive fabric layer (120) through the dielectric substrate (125).

8. The method according to claim 6 or 7, wherein the producing the ablation pattern (505) comprises forming the conductive part (321) as an antenna having at least a first radiating edge (205) and a second radiating edge (206) at a first frequency, and separating said first radiating edge (205), from the first area (301) using the ablation pattern (505) of the edge region (610), and loading the first radiating edge (205) with the capacitance of the selected part (335).

9. The method according to claim 8, wherein the producing the ablation pattern (505) comprises extending the selected part (335) over the other parts of the first area (301) as a frequency selective surface (312), wherein the frequency selective surface (312) has a passband at the first frequency, and framing the second area (302) with said frequency selective surface.

10. The method according to any of the claims 3-9, wherein:- providing the combined structure (102) comprising a conductive fabric layer (120) with a sheet resistance less than 100 Q / square, wherein said conductive fabric layer (120) comprises at least 100 threads / dm thread density of electrically conductive threads in two crossing directions, and;- using a combination of pulse repeating frequency and ablation speed that result in the selective removal of the conductive fabric layer at said lines (504) for forming the ablation pattern (505), and;- providing the selected part (335) with a first set of isolated conductive regions (465) having an area between 0.25-25 mm2, and the other parts with a second set of isolated conductive regions (466) having an area between 1-250 mm2such that the area of said second area (302) is at least 4 times as large as the isolated conductive regions of the selected part (335), wherein;- forming said ablation pattern (505) to form said first (465) and second (466) set of isolated conductive regions.

11. The method according to any of the preceding claims, wherein the second area (302) is framed with a frequency selective surface (302).

12. The method according to any of the preceding claims, wherein the combined structure (102) is a laminate comprising the conductive fabric layer (120) and a dielectric substrate (125) fixedly adhered together.

13. The method according to any of the preceding claims, wherein the non-conductive part (320) is created in the first area (301) after the ablation pattern (505) is formed.

14. The method according to claim 13, wherein the non-conductive part (320) part no longer conducts due to the selective removal of the conductive material and wherein said non-conductive area (320) is electrically non-continuous at a first frequency of a microwave signal, or at a DC current, due to plurality of electrically isolated patches of the conductive fabric layer 120 that remain fixedly attached to the substrate after the selective laser ablation, and are isolated from adjacent patches due to the selective laser removal.

15. The method according to any of the preceding claims, wherein the non-conductive part (320) comprises a plurality of electrically isolated patches of the conductive fabric layer (120) that remain fixedly attached to the substrate after the selective laser ablation.

16. A fabric RF component (101), characterized in that; the fabric RF component (101) comprises:- a combined structure (102) comprising a conductive fabric layer (120) fixedly attached on a dielectric substrate (125), wherein the conductive fabric layer (120) comprises a first area (301) and a second area (302); and- an ablation pattern (505) produced with a laser beam (402) with a varying pattern density on the first area (301 ) of the conductive fabric layer (120) that is configured to form a non-conductive part (320) of the fabric RF component (101) so that the pattern density of the ablation pattern (505) is greater at a selected part (335) of the first area (301) than other parts of the first area (301 ), wherein the second area (302) of the conductive fabric layer without the ablation pattern forms the conductive part (321 ) of the fabric RF component (101).

17. The fabric RF component (101) according to claim 16, characterized in that;- the ablation pattern (505) is formed with selectively removed lines (504) from a first surface of said conductive layer (120) to a surface of the dielectric substrate (125) that is fixedly attached to said conductive layer, and without being cut through the opposite surface of said dielectric substrate (125) under said lines (504), and wherein said lines being cut with a line width of 10-200 urn on the conductive fabric layer (120) wherein the sheet resistance of said conductive fabric layer is less than 100 Q / square, wherein said conductive fabric layer (120) comprises at least 100 threads / dm thread density of electrically conductive threads in two crossing directions, and;- wherein the selected part (335) comprises a first set of isolated conductive regions (465) having an area between 0.25-25 mm2, and the other parts of the first area (301), comprises a second set of isolated conductive regions (466) having an area between 1-250 mm2wherein the area of said second area (302) is at least 4 times as large as the isolated conductive regions of the selected part (335), wherein; said ablation pattern (505) forms said first (465) and second (466) set of isolated conductive regions with a plurality of crossing lines (504).

18. The fabric RF component (101) according to claim 16 or 17, characterized in that; the fabric RF component (101) is produced by the method according to any of the claims 1-15.

19. The fabric RF component (101) according to any of claims 16-18, characterized in that; the fabric RF component (101) is configured as a radiating layer (710) of a layered compound (712), wherein said compound (712) forms a shell of a clothing, helmet, sail, cushioning, upholstery, thermal insulator, footwear, automotive interior, automotive body, fuselage, or drone.

20. A wireless communication device comprising the fabric RF component (101) according to any of the claims 16-19, wherein the wireless communication device is configured to exchange wireless signals (715) via the fabric RF component (101).

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