The subject matter herein relates generally to electronic textiles, and more particularly, to termination methods and interconnects for electronic textiles.
Electronic textiles (e-textiles) are known and used as wearable technology, such as intelligent clothing or smart clothing, that allow for the incorporation of built-in technological elements in textiles and/or clothes. E-textiles may be used in many different applications, including first responder (e.g. fire and police) worn electronics systems, maintenance technician worn electronics systems, soldier worn electronics systems and the like. E-textiles are typically fabrics that enable computing, digital components and electronics to be embedded in them. E-textiles typically have electronic devices, such as conducting wires, integrated circuits, LEDs, conventional batteries and the like, mounted into garments. Some e-textiles have electronic functions incorporated directly on the textile fibers.
Known e-textiles are not without disadvantages. For example, the means of attaching or terminating electronic interconnects directly to the fabric is accomplished by means of soldering or crimping. Soldering poses an issue because it is difficult to strip un-insulated conductive fibers from the surrounding woven fabric's insulative material. Additionally, the woven fabric's insulative material cannot withstand the high temperatures of soldering. Furthermore, crimping to un-insulated conductive fibers of e-textiles has proven less reliable and difficult. For example, known e-textiles use a crimp similar to crimps used for Flat Flex Circuits (FFC). However, because the un-insulated conductive fibers are woven into the fabrics, the terminals crimped to the fabrics have few points of contact with the conductive fibers, and thus the electrical connection therebetween is less reliable. For example, the electrical connection has high resistance and/or intermittent signals.
A need remains for a termination method for e-textiles that creates a more reliable connection in terms of electrical conductivity and/or strength.
In one embodiment, a connector is provided for an e-textile that has conductors that define a conductive layer of the e-textile. The connector has a terminal that may have a mating end and a mounting end. The mounting end is configured to be terminated to one or more of the e-textile's conductors. The mating end can be configured to be mated with a mating contact of a mating component and/or mating connector. The terminal has a body and a plurality of tines extending from the body. A base is separately provided from the terminal and is arranged opposite the body of the terminal such that the e-textile's conductor is positioned between the base and the body of the terminal. The terminal is crimped to electrically connect the terminal and the base to the e-textile's conductor. The tines are folded against or into the base to electrically connect the terminal to the base. The body of the terminal and the base are configured to engage the e-textile's conductors.
In another embodiment, an e-textile is provided having a conductive layer that includes conductors along with a separate connector having a terminal and a base separately provided from the terminal. The terminal has a mating end and a mounting end. The mounting end is terminated to the e-textile's conductors. The mating end is configured to be mated with a mating contact of a mating component and/or mating connector. The terminal has a body and a plurality of tines extending from the body. The base is arranged opposite the body of the terminal such that the conductors are positioned between the base and the body of the terminal. The terminal is crimped to electrically connect the terminal and the base to the e-textile's conductor. The tines are folded against or into the base to electrically connect the terminal to the base. The body of the terminal and the base engage the e-textile's conductors.
In a further embodiment, an e-textile is provided having a conductive layer that includes conductors along with a separate connector having a terminal that has a mating end and a mounting end with the mounting end being terminated to the e-textile's conductors. The mating end is configured to be mated with a mating contact of a mating component. The terminal has a body that is ultrasonically welded to the e-textile's conductor. Optionally, a base may be arranged and provided on the opposite side of the e-textile's conductor and ultrasonically welded to the e-textile's conductor with the terminal welded on the opposite side of the e-textile's conductor.
The e-textile 102 extends between a first electronic device 104 and a second electronic device 106. Any number of electronic devices may be utilized with the wearable article 100. In an exemplary embodiment, the first electronic device 104 constitutes a battery pack and the second electronic device 106 constitutes an LED array that may be powered by the battery pack. Other types of electronic devices may be incorporated into the wearable article 100 in alternative embodiments, such as a computer, personal radio, loop antenna, heating element, display screen, input device, sensor, induction loop or other components known to the industry.
The uninsulated conductors 112 are woven into the insulative fabric 114 such that the conductors 112 have a woven shape, where the conductors 112 weave between both opposing sides of the fabric 114. The e-textile 102 may have any number of layers and the conductors 112 may be provided in one or more of the layers. The layers may or may not be constructed as a weave, where a weft fiber and warp fiber are bi-directionally woven together. The conductors 112 are woven into the fabric 114 such that portions of the conductors 112 are exposed along a first surface 118 of the fabric 114 and portions of the conductors 112 are exposed along a second surface 120 of the fabric 114. The conductors 112 follow generally parallel paths through the fabric 114. The conductors 112 may be arranged at a predetermined spacing or pitch.
The e-textile 102 includes a connector 130 that is electrically connected to the conductors 112. The connector 130 provides an interface for the e-textile 102 for mating with the electronic device 104 or 106 (both shown in
Optionally, the terminals 134 may be formed as part of a leadframe with a carrier extending therebetween that is later entirely or selectively removed to separate one or more of the terminals 134. The bases 136 are separate from, and spaced apart from, the terminals 134 such that a receiving space 138 is defined therebetween. The conductors 112 extend through the receiving space 138 between the terminals 134 and corresponding bases 136 and are compressed between the terminals 134 and corresponding bases 136 to electrically connect the terminals 134 to the conductors 112.
A compressive crimp electrically connects the terminals 134 and the bases 136 to the conductors 112. The terminals 134 are crimped during a crimping process in which the bases 136 are compressed toward the terminals 134, sandwiching the conductors 112 between the terminals 134 and the bases 136. The compressive crimp helps to ensure adequate electrical connection between the terminals 134 and the conductors 112 exposed along the first surface 118 of the fabric 114 and between the bases 136 and the conductors 112 exposed along the second surface 120. When the terminals 134 are crimped, portions of the terminals 134 engage the bases 136 such that the terminals 134 and the bases 136 are electrically connected together. When crimped, the terminals 134 force the bases 136 against the conductors 112. As the bases 136 are compressed downward against the conductors 112 and the fabric 114, the conductors 112 and the fabric 114 are also pressed downward against the terminals 134. As such, the conductors 112 are compressed against the terminals 134 and the bases 136 thus making a more reliable electrical connection between the conductors 112, the terminals 134 and the bases 136 due to the increased surface area and/or points of contact.
In an exemplary embodiment, both the terminal 134 and the base 136 increase the surface area and/or create multiple points of contact with the corresponding conductor 112. For example, the conductor 112 may be exposed at more than one longitudinal spaced apart location along the first surface 118 and at more than one longitudinal spaced apart location along the second surface 120. Where the conductor 112 is exposed at the first surface 118, the terminal 134 makes directs electrical contact with the conductor 112. Where the conductor 112 is exposed at the second surface 120, the base 136 makes directs electrical contact with the conductor 112. The terminals 134 and bases 136 are spaced apart from other terminals 134 and bases 136 to achieve a target impedance for the connector 130.
Each terminal 134 includes a mating end 140 and a mounting end 142 opposite the mating end 140. The mounting end 142 is configured to be mounted to the corresponding conductor 112. The mating end 140 is configured to be mated with a mating contact of a mating component, such as a mating connector of the electronic device 104 or 106 (shown in
The terminal 134 has a body 144 extending between the mating and mounting ends 140, 142. A plurality of tines 146 extend from the body 144. In an exemplary embodiment, the body 144 may be generally planar at the mounting end 142. The tines 146 extend generally perpendicular from the body 144. In an exemplary embodiment, distal ends of the tines 146 may be pointed. The tines 146 are configured to be pressed and pierced through the insulative fabric 114. The tines 146 are then crimped by bending the tines 146 and/or folding the tines 146 inward. Any number of tines 146 may be provided. In an exemplary embodiment, the tines 146 are provided on both sides of the body 144. A space is defined between the tines 146 on opposite sides of the body 144. The conductor 112 is received in the space between the tines 146 on the opposite sides of the body 144.
In an exemplary embodiment, the bases 136 are held by a carrier 150. The carrier 150 holds the bases 136 in a spaced apart relation that corresponds with the spacing between the terminals 134. In the illustrated embodiment, the carrier 150 constitutes a carrier strip, wherein the bases 136 and the carrier strip are stamped from a common blank. The carrier strip is integrally formed with the bases 136 and is formed from the same material. Optionally, the carrier 150 may be removed after the terminals 134 are crimped. Alternatively, the carrier 150 may remain intact and coupled to the bases 136 after the terminals 134 are crimped. When the carrier 150 remains, the bases 136 are electrically connected together. When the carrier 150 remains, the bases 136, the terminals 134 and the conductors 112 are ganged together to increase the current carrying capacity of a common circuit created by the carrier 150.
The connector 130 may be programmable by selecting certain combinations of the bases 136 and/or terminals 134 to remain electrically commoned together. Selected terminals 134 and/or bases 136 may be ganged together to perform a common function, such as to transmit power or data along each of the ganged terminals 134 and/or bases 136. Different sets of terminals 134 and/or bases 136 may be ganged together in different embodiments depending on the particular application. For example, the terminals 134 and/or bases 136 may be initially formed as a lead frame with connecting segments between each of the terminals 134 or the bases 136 such that all of the terminals 134 or bases 136 are initially connected together. Any of the connecting segments may be removed, such as by cutting the connecting segment, to separate the adjacent terminals 134 or bases 136 from one another. Depending on which connecting segments are removed, the terminals 134 and/or bases 136 may cooperate with one another to perform a common function.
The bases 136 are generally planar and have a first side 152 and a second side 154. The bases 136 are mounted to the fabric 114 such that the first side 152 of the bases 136 face, and engage, the exposed portions of the conductors 112 on the second surface 120 of the fabric 114. When the tines 146 are crimped, the tines 146 are folded inward onto the bases 136. The tines 146 engage the second side 154 of the bases 136 and push the bases 136 downward toward the conductors 112 and the body 144 of the terminals 134. Optionally, the tines 146 may pierce through the bases 136 when the tines 146 are crimped. During the crimping process, the bases 136 are forced downward toward the body 144, which compresses the conductors 112 and the fabric 114. Such compression ensures more reliable electrical contact between the bases 136 and the terminals 134 with the conductors 112. The conductors 112 may be at least partially flattened when compressed, creating a larger surface area for the bases 136 and the terminals 134 to engage.
Outer fabric layers 160, 162 may be provided on one or both sides of the e-textile 102. The outer fabric layers 160, 162 may define the exposed layers of the wearable article 100 (shown in
The housing 132 holds the terminals 134 for coupling the terminals 134 to the conductors 112. The mating ends 140 extend forward from the housing 132 and are positioned for mating with a mating component, such as the electronic device 104 or 106 (shown in
As shown in
The compressive crimp provides a more reliable electrical connection between the terminals 134 and bases 136 and the conductors 112. Because the conductors 112 along both longitudinal surfaces 118, 120 are compressed during the crimping process, the contact area between the bodies 144, the bases 136 and the conductors 112 are increased. Optionally, the conductors 112 may be at least partially flattened out during the compression thereof, increasing the amount of contact area of the conductors 112. The increased contact area allows an increase in the current carrying capability of the connection between the connector 130 and the e-textile 102.
Optionally, each of the bases 136, or any number of the bases 136, may be electrically connected together using the carrier 150 (shown in
The mating ends 140 constitute pin contacts that are configured to be received in sockets of the mating connector. Other types of mating interfaces may be provided at the mating ends 140, such as socket contacts, spring contacts, or other mating interfaces known to the industry.
Each terminal 234 extends between a mating end 240 and a mounting end 242. The mounting end 242 is substantially similar to the mounting end 142 (shown in
The terminal 234 includes tines 246 that are folded over during a crimping process. The tines 246 press against the base 236 to compressively crimp the terminal 234 and base 236 to the corresponding conductor 212.
A housing 332 is mounted to the e-textile 302 around the connector 330. The housing 332 is used to couple the connector 330 and e-textile 302 to a mating connector. A boot 334 is provided on the e-textile 302 and may be slid over a rear end of the connector 330 and the housing 332 to provide strain relief and an environmental seal. The connector 330 may include other components in addition to those illustrated herein, such as a cover, a shield, other mating components, and the like.
Bases 536 are provided separately from terminals 534. A carrier 550 holds the bases 536. In the illustrated embodiment, the carrier 550 constitutes a carrier strip that is integrally formed with the bases 536. The carrier 550 and the bases 536 are stamped from a common blank. The carrier 550 and the bases 536 are manufactured from the same material during a common forming process. Optionally, the carrier 550 may be removed from the bases 536 after the bases 536 and terminals 534 are crimped to the conductors 512 of the e-textile 502. Alternatively, the carrier 550 may remain attached to bases 536. The carrier 550 may thus be used to gang the bases 536 together to increase the current carrying capacity and/or common circuits as required by the application of the connector 530.
Each terminal 534 includes a body 544 and tines 546 extending from the body 544. The tines 546 extend through the fabric of the e-textile 502 and are crimped during a crimping process. When the tines 546 are crimped, the base 536 is pressed downward towards the body 544 of the terminal 534. The compression of the base 536 causes the fabric 514 and conductor 512 of the e-textile 502 to be compressed. Such compression crimp creates a more reliable electrical connection between the terminal 534 and base 536 and the conductor 512 due to the increased surface area and/or points of contact.
In an exemplary embodiment, the mounting ends 642 of the terminals 634 are ultrasonically welded to the conductors 612. During the ultrasonic welding process, high frequency ultrasonic acoustic vibrations are locally applied to the terminals 634 under pressure to create a solid state weld between the terminals 634 and the conductors 612. Optionally, bases or slave pieces (not shown) may be provided on opposite sides of the conductors 612 from the terminals 634. The conductors 612 may be ultrasonically welded to, and between, the bases or slave pieces and the terminals 634.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
The present application relates to and claims priority from Provisional Application Ser. No. 61/384,593 filed Sep. 20, 2010, titled “INTERCONNECT OR TERMINATION METHODOLOGY FOR E-TEXTILES”, the complete subject matter of which is hereby expressly incorporated by reference in its entirety. The present application relates to U.S. patent application having, Ser. No. 13/236,380 titled “CONNECTORS FOR E-TEXTILES” and filed on the same day as the present application, the complete subject matter of which is hereby expressly incorporated by reference in its entirety.
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