Patent Application
20190289927
Embodiments disclosed herein relate generally to wearable technology and more specifically to components for garments and textile products that allow electrical connection to electrically conductive lines such as conductive yarn or wire within the garment or textile product.
In wearable technology applications, electrically conductive lines such as yarns are typically embedded within garments and under fabric substrates which form the outer surfaces of the garments. These conductive lines may be connected to electronic devices embedded within the garment. In order to supply electrical power to such devices and to establish an electrical connection with such devices it is necessary to provide an electrical contact on the surface of the fabric substrate.
In order to provide electrical heating within a garment, electrical heating elements may be embedded within the garment. The heating elements require much larger currents than applications such as sensing. In order to supply such currents to the heating elements the resistance of any connecting elements must be minimised, otherwise the currents may cause resistive heating in the connecting elements.
The construction of such electrical contact must be robust so that it is not damaged during use of the garment. The use of the garment may involve exposure to stresses and strains, and exposure to water and sweat. Further, garments and therefore the electrical connections contained within them must be robust enough to not be damaged during cleaning or laundering which may involve exposure to water, detergents and solvents used in dry cleaning.
Further, it is advantageous if both the construction of the electrical connection and the conductive lines are thin and therefore do not interfere with the fit, user physical and psychological comfort or performance of the garment.
According to a first aspect of the present invention, there is provided a component for a garment or textile product. The component comprises a fabric substrate having a first surface and a second surface opposing the first surface; a contact pad formed from an electrically conductive material, the contact pad being configured to engage with a connector and arranged on the first surface of the fabric substrate; a conductive layer electrically coupled to the contact pad; and an electrically conductive line mechanically coupled to, and in electrically conductive contact with, the conductive layer.
The fabric substrate forms part of the garment or textile product. The garment or textile product may, for example have an electronic device such as a sensor or a heating element embedded within. This device may be connected to the conductive line. Thus the contact pad allows an external electrical connection to be made with the electronic device. Embodiments of the present invention provide a durable connection between the contact pad and the conductive line. It is important that the electrical connection between the contact pad and the conductive line is durable as the garment or textile product may be subjected to stresses and strains caused by washing and/or cleaning or the garment and the garment may also be exposed to water and sweat during use. The incorporation of the conductive layer to which the conductive line is attached facilitate this durable connection as the conductive layer provides a larger contact area therefore a more durable connection than a connection between the conductive yarn and the contact pad alone.
In some embodiments, the conductive line may be a conductive wire connected to a heating device. The conductive layer may be formed as a metal washer. Such embodiments provide a large connection area which in addition to the durable connection described above also provide a low resistance connection. This is particularly advantageous in heating application where large currents are required. The metal washer may have a thickness of less than 0.5 mm.
In some embodiments, the conductive layer is coupled to the second surface of the fabric substrate. The conductive layer may have a thickness of less than 0.2 millimetres. An electrical connection between conductive layer and the contact pad may be established by a coupling member. The electrically conductive line may comprise a conductive yarn having a thickness of less than 0.3 millimetres.
In some embodiments, the thickness dimensions mentioned above are optional.
In an embodiment, a Thermoplastic polyurethane (TPU) layer is provided between the between the fabric substrate and the conductive fabric section.
TPU layers may be provided either side of the conductive layer to encapsulate and thereby protect the conductive layer.
The contact pad may be configured to engage with the connector magnetically and/or mechanically.
Multiple conductive yarns may be connected to the conductive layer.
The coupling member may be formed from an elongate member extending from the contact pad. The inclusion of the conductive layer in the component allows a robust connection even when a relatively thin conductive yarn is used. Thus in some embodiments, a width of the elongate member is greater than a thickness of the conductive yarn. The contact pad may have one or more elongate legs which are crimped to couple the conductive yarn to the conductive layer. The contact pad and the elongate member may be formed from a rivet.
The conductive yarn may be coupled to the conductive layer by stitching and/or a conductive adhesive.
In an embodiment, the conductive layer is formed from a conductive fabric.
In an embodiment, the conductive layer comprises a first conductive layer section and a second conductive layer section, the first conductive layer section being electrically separated from the second conductive layer section, wherein a first conductive yarn is electrically coupled to the first conductive layer section and a second conductive yarn is coupled to the second conductive layer section.
In an embodiment, the component for a garment or textile product further comprises an encapsulating layer over the conductive yarn and the conductive layer. The encapsulating layer may comprise a waterproofing layer.
In some embodiments, the conductive yarn has a thickness of less than 0.15 millimetres.
According to a second aspect of the present invention there is provided a method of manufacturing a component for a garment or textile product. The method comprises: providing a fabric substrate having a first surface and a second surface opposing the first surface; providing a conductive layer coupled to the first surface of the fabric substrate, the conductive layer having a thickness of less than 0.5 millimetres; piercing an elongate member coupled to a contact pad through the fabric substrate and the conductive layer such that the contact pad is arranged on the first surface of the fabric substrate, the contact pad being configured to engage with a connector and; attaching a conductive line to the conductive layer.
In some embodiments the conductive line passes though the fabric substrate. The conductive line may be a wire. The conductive layer may be formed form a metal washer. The method may further comprise soldering the conductive line to the conductive layer.
According to a third aspect of the present invention, there is provided a method of manufacturing a component for a garment or textile product. The method comprises providing a fabric substrate having a first surface and a second surface opposing the first surface; providing a conductive layer coupled to the second surface of the fabric substrate, the conductive layer having a thickness of less than 0.2 millimetres; arranging a contact pad on the first surface of the fabric substrate, the contact pad being configured to engage with a connector and formed from an electrically conductive material; establishing an electrical contact between the conductive layer and the contact pad; and attaching a conductive yarn in conductive contact with the conductive layer, the conductive yarn having a thickness of less than 0.3 millimetres.
In some embodiments, the thickness dimensions mentioned above are optional.
In an embodiment attaching a conductive yarn in conductive contact with the conductive layer comprises attaching the conductive yarn stitching and/or a conductive adhesive.
In an embodiment, the conductive layer comprises a conductive fabric.
In an embodiment, the method further comprises laying an encapsulating layer over the conductive yarn and the conductive layer. The encapsulating layer may comprise a waterproof layer.
According to a fourth aspect of the present invention, there is provided a method of manufacturing a component for a garment or textile product. The method comprises: providing a fabric substrate having a first surface and a second surface opposing the first surface; providing a conductive layer coupled to the second surface of the fabric substrate, the conductive layer having a thickness of less than 0.2 millimetres; piercing an elongate member coupled to a contact pad through the fabric substrate and the conductive layer such that the contact pad is arranged on the first surface of the fabric substrate and the elongate member establishes an electrically conductive connection between the contact pad and the conductive layer, the configured to engage with a connector and; and attaching a conductive yarn to the layer, the conductive yarn having a thickness of less than 0.3 millimetres.
In some embodiments, the thickness dimensions mentioned above are optional.
In an embodiment, the method further comprises crimping an end of the elongate member.
In an embodiment attaching a conductive yarn in conductive contact with the conductive layer comprises attaching the conductive yarn stitching and/or a conductive adhesive.
In an embodiment, the conductive layer comprises a conductive fabric.
In an embodiment, the method further comprises laying an encapsulating layer over the conductive yarn and the conductive layer. The encapsulating layer may comprise a waterproof layer.
Some embodiments of the present invention are described more fully hereinafter with reference to the accompanying drawings. In the drawings, dimensions may be exaggerated for clarity of illustration. Like reference numerals refer to like elements throughout.
In the following detailed description, only certain embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realise, the described embodiments may preferably be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being “on” another element, it can be directly on the other element or be indirectly on the other element with one or more intervening elements interposed therebetween. Also, when an element is referred to as being “connected to” another element, it can be directly connected to the other element or be indirectly connected to the other element with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements.
A contact pad 120 is located on a surface of the fabric substrate 110. In the arrangement shown in
The conductive layer 130 may be formed from conductive fabric, that is a fabric or textile that can conduct electricity. The conductive layer 130 may be formed from a textile having metal or conductive fibers woven into, or embroidered onto the construction of the fabric. These conductive fibers may be conductive yarns as described in more detail below. The conductive fibers may comprise a non-conductive or less conductive substrate, which is coated or embedded with electrically conductive elements, such as carbon, nickel, copper, gold, silver, stainless steel, aluminium or titanium. The conductive layer may also be formed from any other conductive surface such as a metal sheet, and a flexible plastic surface printed with a conductive layer. The conductive layer may be formed from a conductive rubber or conductive TPU. The conductive layer may be formed from conductive Print, conductive adhesive or conductive TPU, conductive soldering or glue on a substrate, metal yarn embroidery, a conductive non-woven substrate, and/or a conductive gel on a substrate.
The conductive fabric used in embodiments described herein may have a thickness in the range 0.15 to 0.2 millimetres. In some embodiments the conductive fabric has a thickness of less than 0.2 millimetres.
A conductive yarn 140 is attached to the conductive layer 130. As discussed in more detail below, the conductive yarn 140 has an uninsulated terminal section. This uninsulated terminal section is in contact with the conductive layer 130. Thus, the conductive yarn 140 is in electrically conductive contact with the conductive layer 130.
The conductive yarn 140 is also mechanically coupled to the conductive layer 130. In this embodiment, the contact pad 120 has an elongate coupling portion 122 which extends through the fabric substrate 110 and the conductive fabric 130. The end of the coupling portion 122 has a crimped part 124 which holds the conductive yarn 140 against the conductive layer 130. The crimped part 124 and/or the coupling portion 122 of the contact pad 120 are in contact with the conductive layer 130. The contact pad 120 may be formed as a single element made from an electrically conductive material, and comprising the pad portion, the coupling portion 122 and crimped part 124. Thus, an electrical connection exists between the conductive yarn 140 and the contact pad 120.
In the embodiment described above, the conductive yarn 140 is held in place by the crimped part 124 of the contact pad 120. Alternative embodiments are envisaged in which the conductive yarn is attached to the conductive layer 130, and the conductive fabric provides an electrical connection between the coupling portion 122 of the contact pad 120 and the conductive yarn 140.
In embodiments, further layers are added to the component described above. These layers may be intermediate boding layers between the conductive fabric and the fabric substrate. Such layers may also provide the garment or textile product with properties such as insulation, or waterproofing.
Additionally, or alternatively, further layers may be placed over the fabric substrate and/or the conductive fabric to encapsulate the conductive layer and the conductive yarn. Such encapsulation layers may provide protection and electrical insulation of the conductive layer and the conductive yarn. As discussed in more detail below, the conductive yarn may comprise a protective insulating material. In embodiments, the encapsulating layer may cover the conductive yarn and thus provide such protection and insulation.
Any suitable conductive yarn may be used in embodiments of the present invention, provided that there is provided an uninsulated terminal section. In certain embodiments, the entire conductive yarn may be uninsulated, while in other embodiments, the majority of the conductive yarn may be protected by an insulating material. It will be appreciated that the terminal section of the conductive yarn may be provided with an insulating material that is removed from the terminal section of the conductive yarn to provide an uninsulated conductive yarn.
When used herein, the term “yarn” is intended to take its ordinary meaning in the art (long continuous length of interlocked fibres, suitable for use in one or more of the production of textiles, crocheting, knitting, weaving, embroidery and, more particularly sewing), though it is expanded herein to also cover the use of single filaments of a material, such as a metallic filament. Thus, the uninsulated conductive yarn may be a thin metal wire (e.g. a metal filament suitable for use in one or more of the production of textiles, crocheting, knitting, weaving, embroidery and, more particularly sewing), a metal yarn (i.e. interlocking metal fibers), a yarn or filament made from a conductive polymer, and a conductive composite yarn.
A number of different kinds of conductive composite yarns exist. A first type of conductive composite yarn comprises a normal non-conductive yarn's fibres as a core material that is impregnated with at least one conductive material, such as a metal or a non-metallic conductive material, which latter material may be provided in part in a polymer matrix. A second type of conductive composite yarn comprises a normal non-conductive yarn's fibres as a core material that is then wound together with one or more filaments/fibres of a metal and/or a non-metallic conductive material. A third type of conductive composite yarn comprises a non-metallic conductive material, such as carbon nanotubes or graphene along with a polymeric material, wherein the non-metallic conductive material may be distributed homogeneously throughout the polymeric material to provide a conductive yarn, or the non-metallic conductive material is aligned to form a yarn, with a polymer dispersed within the spaces created in said yarn (e.g. a continuous superaligned carbon nanotube yarn as a conductive framework with polyvinyl alcohol inserted into the intertube spaces of the framework, as described in Liu et al. ACS Nano, 2010, 4 (10), pp 5827-5834). The conductive yarn may comprise stainless or other metallic components such as silver, copper, aluminium, and bi-component metal alloys. The conductive yarn may comprise metal yarn combined with polyester/nylon/cotton/wool/silk etc. In some embodiments the conductive yarn comprises metal yarn wrapped around with elastin filament.
In embodiments, the conductive yarns has a thickness of less than 0.3 millimetres, in some embodiments the thickness of the conductive yarn is less than 0.15 millimetres.
Metals that may be included in aspects and embodiments of the invention include, but are not limited to, iron, copper, silver, gold, aluminium, brass, titanium, and platinum and alloys thereof. For example, a metal alloy that may be included herein is stainless steel.
It will be appreciated that when more than one conductive yarn is used in embodiments of the invention, they may be made of the same material or of different materials. For example, silver coated yarns, stainless steel coated yarns, copper wires, and silver wires may all be used in conjunction in certain embodiments of the invention.
The insulating material for the conductive yarn mentioned herein may be any suitable insulating material. For example, the insulating material may be one or more of a varnish, a latex, a silicone polymer, an epoxy resin, a polymeric fluorocarbon, a thermoplastic elastomer, and a polyurethane. Particular insulating materials that may be mentioned herein include a synthetic or natural rubber, a thermoplastic polyurethane or combinations thereof. Other materials that may be mentioned herein include a silicone polymer.
As mentioned above, the purpose of the component 100 is to allow an electrical connection to be established with the conductive yarn 140 which is embedded in or under the fabric substrate 110. A connection to the conductive yarn 140 can be established by coupling a connecting wire to the contact pad 120
In some embodiments, the contact pad 120 is configured to engage with a connector attached to the connecting wire. This is described in more detail with reference to
The connecting wire 350 is attached to a connector 360. The connector 360 has a protrusion 365 which is shaped to fit into the recess 325 of the contact pad 320. A magnet 370 is embedded in the protrusion 365. The magnet 330 embedded in the contact pad 320 and the magnet embedded in the connector 360 are arranged to attract each other. Thus the magnetic attraction between the magnets causes the contact pad 320 to engage with the connector 360.
Various modifications may be made to the arrangement shown in
Further, while in the embodiment shown in
The connecting wire 450 is attached to a connector 460. The connector 460 has a protrusion 470 which is shaped to fit into the recess 425 of the contact pad 420. The protrusion 470 has a lip 475 which is arranged to engage with the protrusions 430 around the edge of the recess 425 in the contact pad 420. Thus the connector 460 and the contact pad 420 are configured to mechanically engage with each other.
Various modifications may be made to the arrangement shown in
The interconnection illustrated in
As shown in
As shown in
As shown in
Then, as shown in
In one embodiment, the fabric substrate 110 and the conductive layer 130 are thermally bonded together and the piercing and crimping steps described above take place before the thermal bonding adhesive has hardened. An advantage of such embodiments is that the bonding layer will harden after piercing and crimping steps and thus water tight seal may be formed.
In some embodiments, a hard and non-stretchable thermal bonding material may be incorporated between the fabric substrate 110 and the conductive layer 130. Such embodiments have the advantage that the component may be more durable and therefore the electrical connections between the conductive yarn and the contact pad can be ensured.
In the embodiment described above with reference to
Advantages of embodiments in which the conductive yarn is attached to the conductive layer are as follows. The contact area in which the conductive yarn and the conductive layer are attached can be made large. This ensures that the physical connection is strong and also ensures that the electrical connection between the conductive yarn and the conductive layer is over a large area which minimises the risk of disconnection. Further, multiple conductive yarns can be connected to the conductive layer.
The contact pad may be in the form of a rivet having a tail portion which is deformed to hold the contact pad in place once the tail portion has pierced the fabric substrate and the conductive fabric.
As shown in
As shown in
The lower part of
As shown in
The lower part of
As shown in
Then, four conductive yarns 640 are laid over the TPU layer 632 in a horizontal direction as shown in
As shown in
The lower part of
The conductive yarns 640 may be attached to the first conductive layer section 624 or the second conductive layer section 626 by any of the methods discussed above such as stitching, either by stitching the conductive yarn itself through the conductive layer or by stitching over a part of the conductive yarn where it overlaps with the conductive layer. Alternatively, the conductive yarn may be attached to the conductive layer with a conductive adhesive. The conductive yarn may be attached to the conductive layer sections by hot melt glue or soldering or gluing with a glue that has electrical conductivity.
Then, two contact pads are added as shown in
The lower part of
The waterproofing layers of TPU may be formed from Bemis 3916.
As shown in the cross section of
The construction shown in
The construction shown in
In embodiments described herein the thickness of the various layers may be as follows: the conductive fabric may have a thickness in the range 0.15 mm to 0.2 mm; the TPU layers may have a thickness in the range 0.05 to 0.15 mm; the fabric substrates may have a thickness in the range 0.2 mm to 2 mm.
The first contact pad 650 and the second contact pad 660 may be formed from metal snaps having a diameter of approximately 10 mm. The thickness of the metal snaps when attached to the fabric layer is typically in the range 0.5 mm to 1.5 mm. In some embodiments the part of the contact pad that is configured to engage with a connector may be arranged as a male or a female connector, when the contact pad is arrange as a male connector, the thickness may be approximately 0.5 mm and when the contact pad is arranged as a female connector the thickness may be approximately 1.5 mm. Here the term thickness refers to the distance between the first contact pad 650 and the crimped portion 654 and/or the distance between the second contact pad 660 and the crimped portion 664.
The coupling member formed from the elongate member extending from the contact pad may have a diameter of 2.5 mm.
The contact pad 705 is arranged on a fabric layer of a garment 709. The contact pad comprises a top substrate 706. A middle layer fabric 707 is arranged below the top substrate 706. A body portion 702 of a snap connector coupled to the contact pad 705 passes through the fabric substrate 706 and the middle layer fabric 707 and has a flanged bottom part below the middle layer fabric 707. A bottom layer fabric 703 covers the body portion 702 of the snap connector. The outer facing surfaces of the fabric substrate 706 and the bottom layer fabric 703 may be covered with waterproof TPU layers such as Bemis 3916. The bottom fabric layer 703 may be attached to the middle fabric layer 707 by a TPU layer such as Bemis 3415. Similarly, the fabric substrate 706 may be attached to the middle fabric layer 707 by a TPU layer such as Bemis 3415.
As shown in
As described above, the component may be encapsulated by waterproof TPU layers and thus provides a sealed and robust connection to a wire from the contact pad.
The embodiment shown in
In embodiments described herein the thickness of the various layers may be as follows: the washer may have a thickness in the range 0.2 mm to 0.5 mm; the TPU layers may have a thickness in the range 0.05 to 0.15 mm; the fabric substrates may have a thickness in the range 0.2 mm to 2 mm.
The fabric substrate described herein may form part of a garment or other object made from such materials (e.g. a bag). When the fabric substrate forms part of garment, the garment may be any wearable object, such as shorts, socks, T-shirts, trousers, leggings, shirts and caps.
Various modifications to the embodiments described above are envisaged. For example, in the embodiments described above, the contact pad and the coupling portion are formed from an integral part; however, alternative embodiments are envisaged in which the connection between the contact pad and the coupling portion is formed during manufacture of the component. For example, a hole may be made through the fabric substrate and the contact pad may be attached over the hole with a conductive adhesive forming the coupling portion and making an electrical connection between the contact pad and the conductive fabric.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/SG2017/050564 | 11/10/2017 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62420348 | Nov 2016 | US |
