Fabric with Circuitry and Electrical Components

FIELD

This relates generally to items with fabric and, more particularly, to items with fabric and electrical components.

BACKGROUND

It may be desirable to form bags, furniture, clothing, and other items from materials such as fabric. Fabric items generally do not include electrical components. It may be desirable, however, to incorporate electrical components into fabric to provide a user of a fabric item with enhanced functionality.

It can be challenging to incorporate electrical components into fabric. Fabric is flexible, so it can be difficult to mount structures to fabric. Electrical components must be coupled to signal paths (e.g., signal paths that carry data signals, power, etc.), but unless care is taken, signal paths may be damaged, or components may become dislodged as fabric is bent and stretched.

SUMMARY

Interlacing equipment (e.g., weaving equipment, knitting equipment, braiding equipment, etc.) may be provided with individually adjustable components. The use of individually adjustable components may allow electrical components to be inserted into and/or embedded in the fabric during the formation of the fabric.

Woven fabric may include warp strands and weft strands. In a Leno weave, a warp strand may include one or more covering strands twisted around a core strand. The covering strands and/or the core strand may be conductive to form a conductive warp strand. The conductive warp strand may form part of a circuit and/or may be connected to an electrical component.

A first electrical connection may couple the electrical component to the core strand and a second electrical connection may couple the electrical component to the covering strand. The two electrical connections may be isolated from one another. To form isolated electrical connections with the core strand and the covering strand, the outer insulating layer of the core strand may have a different melting temperature and/or may be formed from a different material than the outer insulating layer of the covering strand. Arrangements in which different techniques are used to form the two electrical connections such as ultra-violet light curing material in the first electrical connection and soldering material via induction in the second electrical connection may also be used. Heddles may be used to create a gap between the core strand and the covering strand. The first and second electrical connections may be located in first and second respective grooves in the electrical component. The first electrical connection may couple the core strand to a first contact on the electrical component and the second electrical connection may couple the covering strand to a second contact on the electrical component.

A warp strand may include one or more conductive strands and one or more non-conductive strands. The warp strand may include a core and a covering. In some regions of the warp strand, the conductive strand may be located in the core and may be surrounded and insulated by the non-conductive strand. In other regions of the warp strand, the conductive strand may form part of the covering or may be located on an outer surface of the covering to form an electrode and/or to connect to an electrical component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an illustrative fabric item in accordance with an embodiment.

FIG. 2 is a side view of illustrative woven fabric in accordance with an embodiment.

FIG. 3 is a perspective view of illustrative weaving equipment having members that are adjusted to form circuitry and/or to accommodate an electrical component in accordance with an embodiment.

FIG. 4 is a side view of an illustrative conductive strand including a core and a covering in accordance with an embodiment.

FIG. 5 is cross-sectional side view of an illustrative conductive strand including a conductive core and an outer insulating coating in accordance with an embodiment.

FIG. 6 is a top view of an illustrative electrical component having first and second isolated electrical connections to first and second portions of a conductive strand in accordance with an embodiment.

FIG. 7 is a top view of an illustrative electrical component having first and second isolated electrical connections to first and second separated portions of a conductive strand in accordance with an embodiment.

FIG. 8 is a top view of an illustrative electrical component being connected to a first portion of a conductive strand while a first heddle separates a second portion of the conductive strand in accordance with an embodiment.

FIG. 9 is a top view of an illustrative electrical component being connected to a second portion of a conductive strand while a second heddle separates a first portion of the conductive strand in accordance with an embodiment.

FIG. 10 is a top view of an illustrative conductive strand having a covering that twists around a core in different directions in accordance with an embodiment.

FIG. 11 is a top view of the illustrative conductive strand of FIG. 10 after a portion of the covering has been unraveled from the core in accordance with an embodiment.

FIG. 12 is a side view of illustrative weaving equipment including rotating strand sources that twist cover strands around a conductive strand to form a conductive warp strand across which weft strands are inserted in accordance with an embodiment.

FIG. 13 is a side view of the illustrative weaving equipment of FIG. 12 showing how actuators may be used to separate a core strand from covering strands during component insertion operations, strand processing operations, and/or weft insertion operations in accordance with an embodiment.

FIG. 14 is an illustrative woven fabric produced using equipment of the type shown in FIGS. 12 and 13 and including some regions in which cover strands are twisted around a core strand and other regions in which the cover strands are separated from the core strand in accordance with an embodiment.

FIG. 15 is a side view of an illustrative strand having a conductive strand that forms a core in a first part of the strand and a covering in a second part of the strand in accordance with an embodiment.

FIG. 16 is a side view of an illustrative strand having multiple core strands and having a conductive strand that forms a core in a first part of the strand and a covering in a second part of the strand in accordance with an embodiment.

FIG. 17 is a side view of an illustrative strand having a conductive strand that forms a core in a first part of the strand and that is exposed on an outer surface of a covering in a second part of the strand in accordance with an embodiment.

FIG. 18 is a side view of an illustrative strand having multiple conductive strands that form a core in some parts of the strand and that are exposed on an outer surface of a covering in other parts of the strand in accordance with an embodiment.

FIG. 19 is a side view of an illustrative strand showing how a spreading tool may spread apart covering strands to expose a conductive core strand in accordance with an embodiment.

DETAILED DESCRIPTION

Electronic devices, enclosures, and other items may be formed from fabric such as woven fabric, knit fabric, braided fabric, and/or other suitable fabric. The fabric may include strands of insulating and conductive material that form circuitry. Conductive strands may form signal paths through the fabric and may be coupled to electrical components such as light-emitting diodes and other light-emitting devices, integrated circuits, sensors, haptic output devices, and other circuitry.

Interlacing equipment (sometimes referred to as intertwining equipment) may include weaving equipment, knitting equipment, braiding equipment, or any other suitable equipment used for crossing, looping, overlapping, or otherwise coupling strands of material together to form a network of strands (e.g., fabric). Interlacing equipment may be provided with individually adjustable members such as warp strand positioning equipment (e.g., heddles or other warp strand positioning equipment), weft strand positioning equipment, a reed, take-down equipment, let off equipment (e.g., devices for individually dispensing and tensioning warp strands), needle beds, feeders, guide bars, strand processing and component insertion equipment, carriers, and other components for forming fabric items with electrical components. The individual adjustability of these components may allow interlacing operations (e.g., weaving operations, knitting operations, braiding operations, and/or other interlacing operations) to be performed without requiring continuous lock-step synchronization of each of these devices, thereby allowing fabric with desired properties to be woven.

Processing operations such as selectively shielding conductive strands, selectively insulating conductive strands, selectively exposing conductive cores of conductive strands (e.g., to form connections with electrical components and/or to form exposed contact pads, electrodes, etc.), forming selective electrical connections (e.g., solder connections) between electrical components and conductive strands, and/or other processing operations may take place while the conductive strands are being interlaced by the interlacing equipment. This type of in-situ processing of conductive strands may take place during weaving, knitting, and/or braiding so that electrical circuits can be formed in the fabric and/or so that electrical components can be incorporated into the fabric during formation of the fabric.

Items such as item 10 of FIG. 1 may include fabric and may sometimes be referred to as a fabric item or fabric-based item. Item 10 may be an electronic device or an accessory for an electronic device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, a device embedded in eyeglasses or other equipment worn on a user's head, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which fabric item 10 is mounted in a kiosk, in an automobile, airplane, or other vehicle (e.g., an autonomous or non-autonomous vehicle), other electronic equipment, or equipment that implements the functionality of two or more of these devices. If desired, item 10 may be a removable external case for electronic equipment, may be a strap, may be a wrist band or head band, may be a removable cover for a device, may be a case or bag that has straps or that has other structures to receive and carry electronic equipment and other items, may be a necklace or arm band, may be a wallet, sleeve, pocket, or other structure into which electronic equipment or other items may be inserted, may be part of a chair, sofa, or other seating (e.g., cushions or other seating structures), may be part of an item of clothing or other wearable item (e.g., a hat, belt, wrist band, headband, etc.), or may be any other suitable item that incorporates fabric.

Item 10 may include interlaced strands of material such as monofilaments and yarns that form fabric 12. As used herein, “interlaced” strands of material and “intertwined” strands of material may both refer to strands of material that are crossed with one another, looped with one another, overlapping one another, or otherwise coupled together (e.g., as part of a network of strands that make up a fabric). Fabric 12 may form all or part of a housing wall or other layer in an electronic device, may form internal structures in an electronic device, or may form other fabric-based structures. Item 10 may be soft (e.g., item 10 may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., the surface of item 10 may be formed from a stiff fabric), may be coarse, may be smooth, may have ribs or other patterned textures, and/or may be formed as part of a device that has portions formed from non-fabric structures of plastic, metal, glass, crystalline materials, ceramics, or other materials.

The strands of material used in forming fabric 12 may be single-filament strands (sometimes referred to as fibers) or may be threads, yarns, or other strands that have been formed by interlacing multiple filaments of material together. Strands may be formed from polymer, metal, glass, graphite, ceramic, natural materials such as cotton or bamboo, or other organic and/or inorganic materials and combinations of these materials. Conductive coatings such as metal coatings may be formed on non-conductive strands (e.g., plastic cores) to make them conductive. Reflective coatings such as metal coatings may be applied to strands to make them reflective. Strands may also be formed from single-filament metal wire (e.g., bare metal wire), multifilament wire, or combinations of different materials. Strands may be insulating or conductive.

Strands in fabric 12 may be conductive along their entire lengths or may have conductive portions. Strands may have metal portions that are selectively exposed by locally removing insulation (e.g., to form connections with other conductive strand portions and/or to form connections with electrical components). Strands may also be formed by selectively adding a conductive layer to a portion of a non-conductive strand.). Threads and other multifilament yarns that have been formed from interlaced filaments may contain mixtures of conductive strands and insulating strands (e.g., metal strands or metal coated strands with or without exterior insulating layers may be used in combination with solid plastic strands or natural strands that are insulating). In some arrangements, which may sometimes be described herein as an example, fabric 12 may be a woven fabric and the strands that make up fabric 12 may include warp strands and weft strands.

Conductive strands and insulating strands may be woven, knit, or otherwise interlaced to form conductive paths. The conductive paths may be used in forming signal paths (e.g., signal buses, power lines for carrying power, etc.), may be used in forming part of a capacitive touch sensor electrode, a resistive touch sensor electrode, or other input-output device, or may be used in forming other patterned conductive structures. Conductive structures in fabric 12 may be used in carrying electrical current such as power, digital signals, analog signals, sensor signals, control signals, data, input signals, output signals, or other suitable electrical signals.

Item 10 may include additional mechanical structures 14 such as polymer binder to hold strands in fabric 12 together, support structures such as frame members, housing structures (e.g., an electronic device housing), and other mechanical structures.

To enhance mechanical robustness and electrical conductivity at strand-to-strand connections and/or strand-to-component connections, additional structures and materials (e.g., solder, crimped metal connections, welds, conductive adhesive such as anisotropic conductive film and other conductive adhesive, non-conductive adhesive, fasteners, etc.) may be used in fabric 12. Strand-to-strand connections may be formed where strands cross each other perpendicularly or at other strand intersections where connections are desired. Insulating material can be interposed between intersecting conductive yarns at locations in which it is not desired to form a strand-to-strand connection. The insulating material may be plastic or other dielectric, may include an insulating strand or a conductive strand with an insulating coating or insulated conductive monofilaments, etc. Solder connections may be formed between conductive strands and/or between conductive strands and electrical components by melting solder so that the solder flows over conductive strands. The solder may be melted using an inductive soldering head to heat the solder, using hot air to heat the solder, using a reflow oven to heat the solder, using a laser or hot bar to heat the solder, or using other soldering equipment. In some arrangements, outer dielectric coating layers (e.g., outer polymer layers) may be melted away in the presence of molten solder, thereby allowing underlying metal yarns to be soldered together. In other arrangements, outer dielectric coating layers may be removed prior to soldering (e.g., using laser ablation equipment or other coating removal equipment).

Circuitry 16 may be included in item 10. Circuitry 16 may include electrical components that are coupled to fabric 12, electrical components that are housed within an enclosure formed by fabric 12, electrical components that are attached to fabric 12 using welds, solder joints, adhesive bonds (e.g., conductive adhesive bonds such as anisotropic conductive adhesive bonds or other conductive adhesive bonds), crimped connections, or other electrical and/or mechanical bonds. Circuitry 16 may include metal structures for carrying current, electrical components such as integrated circuits, light-emitting diodes, sensors, and other electrical devices. Control circuitry in circuitry 16 may be used to control the operation of item 10 and/or to support communications with item 18 and/or other devices.

Item 10 may interact with electronic equipment or other additional items 18. Items 18 may be attached to item 10 or item 10 and item 18 may be separate items that are configured to operate with each other (e.g., when one item is a case and the other is a device that fits within the case, etc.). Circuitry 16 may include antennas and other structures for supporting wireless communications with item 18. Item 18 may also interact with item 10 using a wired communications link or other connection that allows information to be exchanged.

In some situations, item 18 may be an electronic device such as a cellular telephone, computer, or other portable electronic device and item 10 may form a cover, case, bag, or other structure that receives the electronic device in a pocket, an interior cavity, or other portion of item 10. In other situations, item 18 may be a wrist-watch device or other electronic device and item 10 may be a strap or other fabric item that is attached to item 18 (e.g., item 10 and item 18 may together form a fabric-based item such as a wristwatch with a strap). In still other situations, item 10 may be an electronic device, fabric 12 may be used in forming the electronic device, and additional items 18 may include accessories or other devices that interact with item 10. Signal paths formed from conductive yarns and monofilaments may be used to route signals in item 10 and/or item(s) 18.

The fabric that makes up item 10 may be formed from strands such as yarns (e.g., multifilament strands) and/or monofilaments that are interlaced using any suitable interlacing equipment. With one suitable arrangement, which may sometimes be described herein as an example, fabric 12 may be woven fabric formed using a weaving machine. In this type of illustrative configuration, fabric may have a plain weave, a basket weave, a satin weave, a twill weave, or variations of these weaves, may be a three-dimensional woven fabric, or may be other suitable fabric. This is, however, merely illustrative. If desired, fabric 12 may include knit fabric, warp knit fabric, weft knit fabric, braided fabric, other suitable type of fabric, and/or a combination of any two or more of these types of fabric.

FIG. 2 is a cross-sectional side view an illustrative fabric 12. As shown in FIG. 2, fabric 12 may include strands 80. Strands 80 may include warp strands 20 and weft strands 22. Warp strands 20 and weft strands 22 may extend along respective first and second orthogonal directions. If desired, additional strands that are neither warp nor weft strands may be incorporated into fabric 12. The example of FIG. 2 is merely illustrative. If desired, fabric 12 may have multiple layers of woven strands 80, or single-layer fabric constructions may be used for fabric 12.

FIG. 3 is a perspective view of illustrative interlacing equipment 98 such as weaving equipment. Weaving equipment 98 may be used to weave strands 80 such as warp strands 20 and weft strands 22. Warp strands 20 may be positioned using warp strand positioning equipment such as heddles 64. Heddles 64 may each include an eye mounted on a wire or other support structure that extends between respective positioners 72 (or between a positioner and an associated spring or other tensioner). In some arrangements, heddles 64 may be mechanically driven (e.g., by a dobby). In other arrangements, positioners 72 that move heddles 64 may be motors (e.g., stepper motors) or other electromechanical actuators that are controlled by a controller during weaving operations so that warp strands 20 are placed in desired positions during weaving. In particular, the controller may supply control signals that move each heddle 64 by a desired amount up or down. By raising and lowering heddles 64 in various patterns (e.g., to different heights) in response to control signals from the controller, different patterns of sheds 68 (gaps) between warp strands 20 may be created to adjust the characteristics of the fabric produced by equipment 98.

Weft strands 22 may be inserted into one or more sheds 68 during weaving to form woven fabric 12 (e.g., woven fabric 12 of FIG. 2 or other suitable woven fabric). Weft strand positioning equipment 60 may be used to place one or more weft strands 22 between the warp strands 20 forming each shed 68. Weft strand positioning equipment 60 for equipment 98 may include one or more shuttles and/or may include shuttleless weft strand positioning equipment (e.g., needle weft strand positioning equipment, rapier weft strand positioning equipment, or other weft strand positioning equipment such as equipment based on projectiles, air or water jets, etc.). For example, weft strand positioning equipment 60 of equipment 98 may include an electrically controllable rapier weft strand device or other weft strand insertion equipment that is controlled by a controller. Weft strand positioning equipment 60 may, if desired, be controlled independently of other components in equipment 98. For example, weft strand insertion operations may be temporarily suspended with or without suspending other weaving operations.

Weft strand positioning equipment 60 may insert weft strand 22 into shed 68 across fabric 12 and may, if desired, attach weft strand 22 to a binder on an opposing side of fabric 12 (e.g., a strand that stitches the edges of fabric 12). After each pass of weft strand 22 is made through shed 68, a reed (e.g., a reed member with slots or other openings through which respective warp strands 20 pass, not shown in FIG. 3) may be moved towards fabric 12 to push the weft strand 22 that has just been inserted into shed 68 between respective warp strands 20 against previously woven fabric 12, thereby ensuring that a satisfactorily tight weave is produced. Reed movement may be linear movement or may be rotational movement back and forth about a shaft to approximate linear reciprocating movement. The positioner for the reed may be, for example, a linear actuator that moves the reed towards and away from the edge of fabric 12.

Fabric 12 that has been woven may be gathered on fabric collection equipment such as take-down rollers or other take-down equipment. If desired, take-down equipment may include multiple independently controlled rollers, which may help protect electrical components in fabric 12 while maintaining an appropriate amount of tension in fabric 12. For example, less tension may be applied to portions of fabric 12 where electrical components 26 are located, while other portions of fabric 12 that do not include electrical components may be held under a higher amount of tension.

Electrical components in item 10 such as illustrative electrical component 26 may include discrete electrical components such as resistors, capacitors, and inductors, may include connectors, may include batteries, may include input-output devices such as switches, buttons, light-emitting components such as light-emitting diodes, audio components such as microphones and speakers, vibrators (e.g., piezoelectric actuators that can vibrate), solenoids, electromechanical actuators, motors, and other electromechanical devices, microelectromechanical systems (MEMs) devices, pressure sensors, light detectors, proximity sensors (light-based proximity sensors, capacitive proximity sensors, etc.), force sensors (e.g., piezoelectric force sensors), strain gauges, moisture sensors, temperature sensors, accelerometers, gyroscopes, compasses, magnetic sensors (e.g., Hall effect sensors and magnetoresistance sensors such as giant magnetoresistance sensors), touch sensors, and other sensors, components that form displays, touch sensors arrays (e.g., arrays of capacitive touch sensor electrodes to form a touch sensor that detects touch events in two dimensions), and other input-output devices, electrical components that form control circuitry such as non-volatile and volatile memory, microprocessors, application-specific integrated circuits, system-on-chip devices, baseband processors, wired and wireless communications circuitry, and other integrated circuits.

Electrical components such as component 26 may be bare semiconductor dies (e.g., laser dies, light-emitting diode dies, integrated circuits, etc.) or packaged components (e.g. semiconductor dies or other devices packaged within plastic packages, ceramic packages, or other packaging structures).

As shown in FIG. 3, strands 80 of fabric 12 may include conductive strands 80C. Conductive strands 80C (sometimes referred to as “wires”) may be configured to carry electrical signals (e.g., power, digital signals, analog signals, sensor signals, control signals, data, input signals, output signals, or other suitable electrical current) to and/or from components 26. Strands 80C may be warp strands (e.g., warp strands 20), weft strands (e.g., weft strands 22), or other suitable strands 80 in fabric 12 (e.g., knitted strands, braided strands, inlaid or inserted strands, etc.). If desired, component 26 may be coupled to only a single conductive strand 80C, may be coupled to two conductive strands 80C, or may be coupled to three or more conductive strands 80C. Arrangements in which component 26 is coupled to a pair of conductive strands 80C are sometimes described herein as an illustrative example.

To increase the robustness of the connection between strands 80C and component 26, component 26 may have one or more recesses for receiving strands 80C. For example, strands 80C may each be threaded through a portion of component 26 to help secure component 26 to fabric 12. Strands 80 may be threaded through recesses, openings, trenches, grooves, holes, and/or other engagement features of component 26.

Electrical components 26 may be inserted into fabric 12 during the formation of fabric 12 using component insertion equipment such as insertion tool 54. Insertion tool 54 may hold component 26 and may align component 26 with conductive strands 80C during interlacing operations. If desired, component 26 may be electrically and mechanically connected to one or more conductive strands 80C in a pocket in fabric 12. For example, weaving equipment 98 may be used to create one or more regions in fabric 12 such as a pocket (sometimes referred to as a gap, space, cavity, void, position, location, etc.) for receiving electrical components. Regions in fabric 12 that receive electrical components may be formed by creating a space or gap between portions of fabric 12. The term “pocket” may be used to refer to a void between fabric portions and/or may be used to refer to a position or location between fabric portions (e.g., a position between strands of material in fabric 12).

Following insertion and attachment of component 26 to conductive strand 80C, weaving equipment 98 may continue weaving operations (which may include closing the pocket to fully enclose component 26, if desired) to continue forming fabric 12.

Processing operations such as selectively shielding conductive strands 80C, selectively insulating conductive strands 80C, selectively exposing conductive cores of conductive strands 80C (e.g., to form connections with electrical components and/or to form exposed contact pads, electrodes, etc.), forming selective electrical connections (e.g., solder connections) between electrical components and conductive strands 80C, and/or other processing operations may take place while the conductive strands are being interlaced by the interlacing equipment. This type of in-situ processing of conductive strands 80C may take place during weaving (e.g., while strands 80 and 80C are located on weaving equipment 98) so that electrical circuits can be formed in fabric 12 and/or so that electrical components 26 can be incorporated into fabric 12 during formation of fabric 12.

FIG. 4 is a side view of an illustrative conductive strand 80C that may be used in fabric 12 (e.g., that may be woven with other strands 80 using weaving equipment 98 of FIG. 3). Conductive strand 80C may be a conductive warp strand 20, and conductive weft strand 22, and/or may be any other suitable strand in fabric 12.

In the example of FIG. 4, conductive strand 80C includes a core such as core 32 surrounded by a covering such as covering 30. Core 32 may extend along a longitudinal axis of strand 80 and may include one or more conductive core strands 80C-1 (e.g., a metal monofilament, a bundle of metal filaments forming a multifilament wire, etc.). Conductive strands 80C-1 of core 32 may be insulated (e.g., may include an outer layer of insulating material such as polymer) or may be bare metal wires.

Covering 30 may include one or more conductive covering strands 80C-2 (e.g., a metal monofilament, a bundle of metal filaments forming a multifilament wire, etc.) that are twisted around, braided around, or otherwise wrapped around core 32. Covering 30 may be a single-layer covering, a double-layer covering (e.g., first and second concentric layers of twisted strands that are twisted in the same direction or that are twisted in opposite directions), and/or may have any other suitable number of layers. Conductive covering strands 80C-2 of cover 30 may be insulated (e.g., may include an outer layer of insulating material such as polymer) or may be bare metal wires. Covering 30 may form a twisted or braided sheath around core 32.

In some arrangements, conductive core strands 80C-1 of core 32 and conductive covering strands 80C-2 of cover 30 may be electrically isolated from one another so that covering 30 forms an electrical shielding layer surrounding some or all of the length of conductive core 32. For example, one or both of conductive strands 80C-1 and 80C-2 may have a cross-section of the type shown in FIG. 5.

In the example of FIG. 5, conductive strand 80C (e.g., a conductive strand 80C that forms conductive core strand 80C-1 of core 32 and/or that forms conductive covering strand 80C-2 of covering 30) may include conductive core 34 (e.g., a metal monofilament and/or a metal multifilament) covered by an outer insulating layer 36. Examples of metals that may be used in forming conductive material of core 34 include gold, silver, copper, aluminum, nickel, palladium, molybdenum, platinum, titanium, tungsten, and/or other suitable materials. Other metals may also be used for material 34 of strand 80C. Outer insulating layer 36 may be formed from para-aramid fiber (e.g., Kevlar®), spun aromatic polyester fiber (e.g., Vectran®), and/or other polymer materials.

FIG. 6 is a top view of an illustrative electrical component with selective electrical connections to conductive strands. Conductive strands 80C-1 and 80C-2 may be first and second parallel warp strands in fabric 12, or conductive strands 80C-1 and 80C-2 may be bundled together to form a single conductive strand 80C. For example, conductive strand 80C-1 may be a conductive core strand that forms a core (e.g., core 32 of FIG. 4) and conductive strand 80C-2 may be a conductive covering strand that forms a covering (e.g., covering 30 of FIG. 4) that is twisted, braided, or otherwise wrapped around the core. Each of strands 80C-1 and 80C-2 may be threaded through and independently positioned by a respective heddle such as heddle 64 of FIG. 3, which are controlled using warp strand positioners such as warp strand positioner 72 of FIG. 3.

Heddles 64 may avoid crossing one another during weaving, or heddles 64 may be specialized heddles 64 that can rotate and/or otherwise swap positions to create twisted, braided, or otherwise bundled warp strands 20. Heddles may, for example, be used to form a Leno weave in fabric 12. For example, heddles 64 may be configured to twist conductive strand 80C-2 around conductive strand 80C-1 during weaving, if desired. Weft strands 22 may be held in place between the twisted strands (e.g., between strands 80C-1 and 80C-2).

As shown in FIG. 6, component 26 may include grooves such as grooves 50-1 and 50-2. Grooves 50-1 and 50-2 (sometimes referred to as trenches, openings, notches, recesses, etc.) in component 26 may be formed by removing portions of component 26 (e.g., using a laser, a mechanical saw, a mechanical mill, or other equipment) or may be formed by molding (e.g., injection molding) or otherwise forming component 26 into a shape that includes grooves 50-1 and 50-2. Grooves 50-1 and 50-2 may have a width between 2 mm and 6 mm, between 0.3 mm and 1.5 mm, between 1 mm and 5 mm, between 3 mm and 8 mm, greater than 3 mm, less than 3 mm, or other suitable width. If desired, trenches 50-1 and 50-2 may have different depths (e.g., to expose contact pads that are located at different surface heights of component 26).

Grooves 50-1 and 50-2 may expose conductive pads on component 26. Strands 80C-1 and 80C-2 may be threaded through grooves 50-1 and 50-2 in component 26. A first electrical connection 82-1 (e.g., solder or other suitable conductive material) may be used to electrically and mechanically couple strand 80C-1 to a first contact on component 26 in groove 50-1, and a second electrical connection 82-2 (e.g., solder or other suitable conductive material) may be used to electrically and mechanically couple strand 80C-2 to a second contact on component 26 in groove 50-2.

If desired, electrical connections 82-1 and 82-2 may be electrically isolated form one another. Component 26 may, for example, include terminals such as positive and negative electrodes (e.g., an anode and a cathode), each located in a respective one of grooves 50-1 and 50-2. Conductive strand 80C-1 may be coupled to a first contact (e.g., a first electrode, bond pad, terminal, etc.) in groove 50-1 using solder 82-1, while solder 82-1 remains electrically insulated from conductive strand 80C-2. Conductive strand 80C-2 may be coupled to a second contact (e.g., a second electrode, bond pad, terminal, etc.) in groove 50-2 using solder 82-2, while solder 82-2 remains electrically insulated from conductive strand 80C-1. This may be achieved by using different materials for solder 82-1 and solder 82-2 (e.g., materials with different soldering temperatures), by using different insulation materials for conductive strands 80C-1 and 80C-2, by using different techniques for connections 82-1 and 82-2 (e.g., connection 82-1 may include ultraviolet-light-cured material whereas connection 82-2 may be solder material that is reflowed using induction or other techniques).

While strands 80C-1 and 80C-2 are being held in place by heddles 64, first electrical connection 82-1 may be made selectively between strand 80C-1 and component 26, and second electrical connection 82-2 may be made selectively between strand 80C-2 and component 26. Due to the use of different solder materials, different insulation materials, and/or different connection techniques, connection 82-1 may be electrically insulated from conductive strand 80C-2 and connection 82-2 may be electrically insulated from conductive strand 80C-1. For example, conductive strands 80C-1 and 80C-2 may include outer insulating layers 36 (FIG. 5) that are formed from different materials with different melting temperatures so that the first soldering operation that forms connection 82-1 melts the outer insulating layer 36 of conductive strand 80C-1 without melting the outer insulating layer 36 of conductive strand 80C-2. The second soldering operation that forms connection 82-2 may melt the outer insulating layer 36 of conductive strand 80C-2 without melting the outer insulating layer 36 of conductive strand 80C-1. In this way, component 26 may have a first electrical connection with conductive core strand 80C-1, and a second electrical connection with conductive covering strand 80C-2 that is electrically insulated from the first electrical connection.

FIG. 7 illustrates another technique for selectively connecting component 26 to different portions of a conductive strand. In the example of FIG. 7, heddles 64 may be used to create a gap such as gap G between core 32 and cover 30 of strand 80C. In regions 130, heddles 64 may cross one another (e.g., rotate) to twist, braid, or otherwise wrap covering strand 80C-2 around core strand 80C-1. In region 132, heddles 64 may avoid crossing each other and may instead separate to form gap G between core strand 80C-1 and covering strand 80C-2 across a given length of strand 80C (e.g., a length that can accommodate component 26). This allows separate electrical connections 82-1 and 82-2 to be formed between component 26 and conductive strands 80C-1 and 80C-2. Due to the separation between conductive strands 80C-1 and 80C-2 in region 132, connection 82-1 may be electrically isolated from conductive strand 80C-2, and connection 82-2 may be electrically isolated from conductive strand 80C-1.

In the example of FIGS. 8 and 9, heddles 64 are configured to temporarily separate conductive strands 80C-1 and 80C-2 while electrical connections are selectively formed with component 26. Conductive strands 80C-1 and 80C-2 may be first and second parallel warp strands in fabric 12, or conductive strands 80C-1 and 80C-2 may be bundled together to form a conductive warp strand 80C. For example, conductive strand 80C-1 may be a core strand that forms a core (e.g., core 32 of FIG. 4) and conductive strand 80C-2 may be a covering strand that forms a covering (e.g., covering 30 of FIG. 4) that is twisted, braided, or otherwise wrapped around the core. Strands 80C-1 and 80C-2 may each be threaded through independently controlled heddles 64 and positioned using warp strand positioners such as warp strand positioners 72.

As shown in FIG. 8, a first heddle 64-1 may temporarily separate conductive strand 80C-2 from strand 80C-1 by moving strand 80C-2 away from component 26. A second heddle (not shown in FIG. 8) may position conductive strand 80C-1 so that it aligns with component 26. While heddle 64-1 holds conductive strand 80C-2 away from component 26, soldering tool 38 may be used to create electrical connection 82-1 between component 26 and conductive strand 80C-1 in groove 50-1.

As shown in FIG. 9, a second heddle 64-2 may temporarily separate conductive strand 80C-1 from strand 80C-2 by moving strand 80C-1 away from component 26. Heddle 64-1 (not shown in FIG. 9) may position conductive strand 80C-2 so that it aligns with component 26. While heddle 64-2 holds conductive strand 80C-1 away from component 26, soldering tool 38 may be used to create electrical connection 82-2 between component 26 and conductive strand 80C-2 in groove 50-2.

In the examples of FIGS. 10 and 11, twisting direction changes can be used to create regions of separation between conductive strands 80C-1 and 80C-2 of strand 80C. As shown in FIG. 10, conductive strand 80C may include core strand 80C-1 (e.g., forming core 32 of FIG. 4) and covering strand 80C-2 (e.g., forming covering 30 of FIG. 4). Heddles 64 may twist covering strand 80C-2 around core strand 80C-1. In locations 44 along strand 80C, heddles 64 may change the direction of twisting. In regions 122, covering strand 80C-2 may be twisted around core strand 80C-1 in direction 40. In regions 120, covering strand 80C-2 may be twisted around core strand 80C-1 in direction 42. As shown in FIG. 11, this creates an unraveled region in which covering strand 80C-2 unravels from core strand 80C-1 between locations 44 where heddles 64 changed the direction of twisting. Unraveled segment 48 of conductive covering strand 80C-2 and exposed core segment 46 of conductive core strand 80C-1 in the unraveled region may provide first and second separate locations for forming isolated electrical connections with component 26 (e.g., electrical connections of the type shown in FIG. 7).

FIG. 12 is a side view of illustrative weaving equipment that includes specialized heddles for forming a Leno weave in fabric 12. Specialized heddle structures 126 (sometimes referred to as warp strand positioning structures 126) may include heddle 64 for positioning core strand 80C-1 of core 32 and rotating member 124 for positioning cover strands 80C-2 of cover 30. Core strand 80C-1 and cover strands 80C-2 may form a conductive warp strand 20 in woven fabric 12. Warp strand sources 58 may include bobbins for supplying cover strands 80C-2. Warp strand sources 58 may be attached to rotating member 124 and may be configured to rotate about axis 108 (e.g., in direction 52 or in an opposite twisting direction) to twist cover strands 80C-2 around core strand 80C-1 during weaving.

Warp strand positioning structures 126 may be coupled to one or more actuators such as actuators 116 and 118 (e.g., servomotors or other suitable actuators). Actuator 116 may be configured to adjust the position of rotating member 124 in directions 78 (to thereby adjust the position of cover strands 80C-2), whereas actuator 118 may be configured to adjust the position of heddle 64 in directions 106 (to thereby adjust the position of core strand 80C-1). Actuators 116 and 118 may move strands 80C-1 and 80C-2 in unison and/or may move strands 80C-1 and 80C-2 independently one of another.

Weft strands 22 may be inserted into one or more sheds (e.g., shed 68 of FIG. 3) during weaving to form woven fabric 12. Weft strand positioning equipment 60 (FIG. 3) may be used to place one or more weft strands 22 between the warp strands 20 that are being positioned by warp strand positioning structures 126 such as heddle 64.

During weft strand insertion, actuators 116 and 118 may adjust the respective positions of both core strand 80C-1 and cover strand 80C-2 to create a shed through which a given weft strand 22 can be inserted. FIG. 12 shows possible weft strand insertion locations A, B, C, and D. By using actuator 116 and/or actuator 118 to selectively position respective core strand 80C-1 and cover strands 80C-2, weft strands 22 may be inserted into position A (e.g., above core strand 80C-1 and cover strands 80C-2), position B (e.g., below one of cover strands 80C-2 and above core strand 80C-1 and above the other cover strand 80C-2), position C (e.g., below one of cover strands 80C-2 and core strand 80C-1 and above the other cover strand 80C-2), or position D (e.g., below core strand 80C-1 and cover strands 80C-2).

To accommodate component insertion and/or strand processing operations (e.g., adding and/or removing coatings such as insulating coatings and/or conductive coatings, applying encapsulation material, forming solder connections and/or exposed contact pads, etc.), actuator 118 and/or actuator 116 may be used to position core strand 80C-1 away from cover strands 80C-2, as shown in FIG. 13. This may be achieved by using actuator 118 to move core strand 80C-1 upward along the Z-axis of FIG. 13 and/or by using actuator 116 to move cover strands 80C-2 downward along the Z-axis of FIG. 13 (or vice versa). While cover strands 80C-2 are separated from core strand 80C-1, electrical component 26 may be attached to core strand 80C-1 and/or to cover strand 80C-2, and/or other processing operations may be performed on core strand 80C-1 and/or cover strand 80C-2 (e.g., an outer insulating coating may be removed to expose a conductive core, encapsulation material may be applied to encapsulate an electrical connection between the electrical component and conductive strand, etc.). If desired, some of weft strands 22 may be captured by (trapped between) covering strands 80C-2 and conductive core strand 80C-1 (e.g., by inserting weft strands 22 into location B of FIG. 13).

FIG. 14 is a side view of an illustrative fabric 12 that may be formed using the equipment of FIGS. 12 and 13. Weft strands 22A may be inserted into locations A of FIGS. 12 and 13; weft strands 22C may be inserted into locations C of FIGS. 12 and 13; and weft strands 22D may be inserted into locations D of FIGS. 12 and 13 to obtain the arrangement of FIG. 14. Additional weft strands 22 may be inserted into locations B of FIGS. 12 and 13, if desired. The arrangement of FIG. 14 is merely illustrative.

As shown in FIG. 14, fabric 12 may include some regions such as regions 160 in which cover strands 80C-2 are twisted around core strand 80C-1 (e.g., to form a shielded coaxial cable) and may include some regions such as region 162 in which core strand 80C-1 is separated from cover strands 80C-2 (e.g., in which portions of fabric 12 separate core strand 80C-1 from cover strands 80C-2). In region 162, a segment of core strand 80C-1 may be exposed on a first surface of fabric 12 while segments of cover strands 80C-2 may be exposed on an opposing second surface of fabric 12, if desired. This construction may be achieved for example, by inserting weft strands 22B in location B of FIG. 13 while using heddle structures 126 to separate conductive core strand 80C-1 from covering strands 80C-2.

It may be desirable to selectively expose a conductive core of a conductive strand. For example, a conductive core strand may have a segment that is moved to an outer surface of the strand to form a connection with an electrical component and/or to form an electrode on the conductive strand. Illustrative examples of this type of arrangement are shown in FIGS. 15, 16, 17, and 18.

In the example of FIG. 15, strand 80 includes conductive strand 80C and other strands 80D. Strand 80 may be a warp strand, a weft strand, or any other suitable strand in fabric 12. Strand 80 may, for example, form a warp strand in a Leno weave. Strands 80D may be conductive or non-conductive. In region 86, conductive strand 80C and two of strands 80D are twisted around a given strand 80D in direction 92. This causes the given strand 80D to form a core strand while the remaining strands 80D and 80C form covering strands in region 86.

In region 88, conductive strand 80C swaps places with the given strand 80D at the core of strand 80. All three strands 80D are twisted around conductive strand 80C in direction 92 in region 88. This causes conductive strand 80C to form a core strand while the remaining strands 80D form covering strands in region 88. This allows conductive strand 80C to form an exposed outer layer of strand 80 in region 86, while remaining covered (e.g., insulated and/or shielded) in region 88. Conductive strands 80C may form electrodes and/or electrical connections with electrical components in regions 86.

The technique of swapping core strands and cover strands may be applied to strands with multiple core strands, as shown in the example of FIG. 16. As shown in FIG. 16, strand 80 may include conductive strands 80C, non-conductive strand 80N, and other strands 80D, which may be conductive or non-conductive. Strand 80 may be a warp strand, a weft strand, or any other suitable strand in fabric 12. Strand 80 may, for example, form a warp strand in a Leno weave.

Strand 80 may include core 32 and covering 30. In regions 102, non-conductive strand 80N may form covering 30 that twists around strands 80D and 80C of core 32. In other words, non-conductive strand 80N may be a covering strand in regions 102 and strands 80D and 80C may be core strands in regions 102.

In region 104, conductive strand 80C swaps places with non-conductive strand 80N. Non-conductive strand 80N moves from a covering location to a core location to become a core strand in core 32 in region 104. Conductive strand 80C moves from a core location to a covering location to become a covering strand in covering 30 in region 104. If desired, strands 80D may form part of covering 30 in other regions along the length of strand 80. This allows conductive strands such as strand 80C and/or other strands 80D to form an exposed outer layer of strand 80 in regions such as regions 104, while remaining covered (e.g., insulated and/or shielded) by non-conductive strand 80N in regions 102. Conductive strands 80C may form electrodes and/or electrical connections with electrical components in regions 104.

In the example of FIG. 17, strand 80 may include conductive strands 80C, non-conductive strand 80N, and other strands 80D, which may be conductive or non-conductive. Strand 80 may be a warp strand, a weft strand, or any other suitable strand in fabric 12. Strand 80 may, for example, form a warp strand in a Leno weave.

Strand 80 may include core 32 and covering 30. In regions 94, non-conductive strand 80N may form covering 30 that twists around strands 80D and 80C of core 32. In other words, non-conductive strand 80N may be a covering strand in regions 94 and strands 80D and 80C may be core strands in regions 94.

In region 96, conductive strand 80C is pulled outside of non-conductive strand 80N while non-conductive strand 80N keeps twisting around core 32. Non-conductive strand 80N may be interposed between conductive strand 80C and core 32 in region 96. Conductive strand 80C moves from a core location to a location outside of covering 30 to form an exposed conductor on covering 30 in region 96. If desired, strands 80D may form exposed conductors on the outside covering 30 in other regions along the length of strand 80. This allows conductive strands such as strand 80C and/or other strands 80D to form an exposed outer layer of strand 80 in regions such as regions 96, while remaining covered (e.g., insulated and/or shielded) by non-conductive strand 80N in regions 94. Conductive strands 80C may form electrodes and/or electrical connections with electrical components in regions 96.

In the example of FIG. 18, different conductive core strands are selectively exposed at different locations along the length of the strand. Strand 80 may include conductive strands 80C-1 and 80C-2, non-conductive strand 80N, and other strands 80D, which may be conductive or non-conductive. Strand 80 may be a warp strand, a weft strand, or any other suitable strand in fabric 12. Strand 80 may, for example, form a warp strand in a Leno weave.

Strand 80 may include core 32 and covering 30. In regions 94, non-conductive strand 80N may form covering 30 that twists around strands 80D, 80C-1, and 80C-2 of core 32. In other words, non-conductive strand 80N may be a covering strand in regions 94 and strands 80D, 80C-1, and 80C-2 may be core strands in regions 94.

In region 96-1, conductive strand 80C-1 is pulled outside of non-conductive strand 80N while non-conductive strand 80N keeps twisting around strands 80D and 80C-2 of core 32. Conductive strand 80C-1 moves from a core location to a location outside of covering 30 to form an exposed conductor on covering 30 in region 96-1.

In region 96-2, conductive strand 80C-2 is pulled outside of non-conductive strand 80N while non-conductive strand 80N keeps twisting around strands 80D and 80C-1 of core 32. Conductive strand 80C-2 moves from a core location to a location outside of covering 30 to form an exposed conductor on covering 30 in region 96-2.

If desired, strands 80D may form exposed conductors on the outside covering 30 in other regions along the length of strand 80. This allows conductive strands such as strand 80C and/or other strands 80D to form an exposed outer layer of strand 80 in regions such as regions 96-1 and 96-2, while remaining covered (e.g., insulated and/or shielded) by non-conductive strand 80N in regions 94. Conductive strands 80C-1 and 80C-2 may form electrodes and/or electrical connections with electrical components in regions 96-1 and 96-2.

FIG. 19 shows an illustrative arrangement in which a conductive core strand is temporarily exposed using a spreading tool. As shown in FIG. 19, strand 80 may include core 32 and covering 30. Strand 80 may be a warp strand, a weft strand, or any other suitable strand in fabric 12. Strand 80 may, for example, form a warp strand in a Leno weave.

Core 32 may be formed from one or more conductive strands such as conductive strand 80C. Covering 30 may be formed from strands 80D, which may be insulating or conductive. Using spreading tool 110 (e.g., first and second needles or other elongated members), covering 30 may be pulled in directions 112 to expose segment 114 of conductive strand 80C of core 32. While spreading tool 110 is separating covering 30 in directions 112, an electrical component such as component 26 (FIG. 3) may be mounted to conductive strand 80C of core 32, or other strand processing operations may be performed on the exposed conductive strand 80C of core 32.

The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Fabric with Circuitry and Electrical Components

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