Method for making non-planar radio frequency device and device produced thereby
First Claim
1. A method for making a non-planar radio frequency (RF) device using a mold having a corresponding non-planar shape including a generally spherical portion, the method comprising the steps of:
- forming an electrical conductor pattern on a flexible substrate;
positioning and stretching the flexible substrate onto the mold having the non-planar shape including the generally spherical portion so that the electrical conductor pattern is exposed;
forming a rigid layer on the flexible substrate so that at least a portion of the exposed electrical conductor pattern will be transferred to the rigid layer upon separation from the flexible substrate; and
separating the rigid layer from the flexible substrate with at least a portion of the electrical conductor pattern remaining on the rigid layer.
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Accused Products
Abstract
A method for making an RF device, such as an antenna, having a non-planar shape with a high degree of accuracy includes the steps of forming an electrical conductor pattern on a flexible substrate, and positioning the flexible substrate onto the mold having the non-planar shape so that the electrical conductor pattern is exposed. The method also includes forming a rigid layer on the flexible substrate so that the exposed electrical conductor pattern will be transferred to the rigid layer upon separation from the flexible substrate. The rigid layer is separated from the flexible substrate with the electrical conductor pattern remaining on the rigid layer. The method preferably further includes forming an additional thickness of conductive material onto the electrical conductor pattern remaining on the rigid layer. The electrical conductor pattern may be a metal pattern which may be printed onto the substrate. In other embodiments, the electrical conductor pattern on the flexible substrate may be replaced by a seed material that will later be receptive to metal deposition to the define the conductive portions.
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Citations
39 Claims
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1. A method for making a non-planar radio frequency (RF) device using a mold having a corresponding non-planar shape including a generally spherical portion, the method comprising the steps of:
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forming an electrical conductor pattern on a flexible substrate; positioning and stretching the flexible substrate onto the mold having the non-planar shape including the generally spherical portion so that the electrical conductor pattern is exposed; forming a rigid layer on the flexible substrate so that at least a portion of the exposed electrical conductor pattern will be transferred to the rigid layer upon separation from the flexible substrate; and separating the rigid layer from the flexible substrate with at least a portion of the electrical conductor pattern remaining on the rigid layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method for making a non-planar Radio Frequency (RF) device including conductive portions using a mold having a corresponding non-planar shape including a generally spherical portion, the method comprising the steps of:
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forming a pattern of a first material on a flexible substrate; positioning and stretching the flexible substrate onto the mold having the non-planar shape including the generally spherical portion so that the pattern of the first material is exposed; forming a rigid layer on the flexible substrate and separating the rigid layer from the flexible substrate so that at least a portion of the exposed pattern of the first material is transferred to and remains on the rigid layer upon separation from the flexible substrate; and forming a layer of electrically conductive material on the pattern of first material remaining on the rigid layer. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A method for making a non-planar antenna including electrically conductive portions using a mold having a corresponding non-planar shape including a generally spherical portion, the method comprising the steps of:
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forming an electrical conductor pattern on a flexible substrate; positioning and stretching the flexible substrate onto the mold having the non-planar shape including the generally spherical portion so that the electrical conductor pattern is exposed; and forming a rigid layer on the flexible substrate and separating the rigid layer from the flexible substrate so that at least a portion of the exposed electrical conductor pattern is transferred to and remains on the rigid layer upon separation from the flexible substrate. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32)
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33. An antenna comprising:
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a rigid body portion having a generally spherical shape; a predetermined pattern of a first electrically conductive layer on an interior surface of said rigid body portion including the generally spherical shape; and a second electrically conductive layer on said first electrically conductive layer. - View Dependent Claims (34, 35)
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36. An intermediate product used during manufacturing of an antenna and comprising:
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a mold having a non-planar shape including a generally spherical portion; a flexible substrate on said mold including the generally spherical portion; a pattern of a first material on said flexible substrate; and a rigid body of material on said flexible substrate with at least a portion of the pattern of first material adhering to the rigid body of material upon separation from the flexible substrate. - View Dependent Claims (37, 38, 39)
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Specification