Smart soft good product, circuitry layer, and methods
First Claim
1. A method for fabricating an article comprising:
- applying a first layer to a first side of a fabric substrate, the first side of the fabric substrate coated with a conductive material, wherein the applied first layer includes a pattern corresponding to a desired region of remaining conductive material, wherein the desired region of remaining conductive material is covered by the mask;
applying a second layer to a second side of the fabric substrate opposite the first side, wherein the applied second layer covers a portion of the second side corresponding to the desired region of remaining conductive material on the first side;
applying a chemical to the fabric substrate to remove conductive material not covered by the first layer;
arranging a conductive portion of a component carrier over an electrode, the electrode defined by at least a portion of the remaining conductive material on the fabric substrate, the component carrier comprising a flexible substrate and a rigid electrical component mounted to the flexible substrate, the conductive portion extending from a terminal of the rigid electrical component across a region of the flexible substrate;
fastening the component carrier to the fabric substrate to form an insert;
forming an electrical connection between the conductive portion and the electrode to form an electrical circuit on the insert; and
inserting the insert into a soft good.
2 Assignments
0 Petitions
Accused Products
Abstract
One variation of a method for fabricating a garment includes: applying a first mask to a first side of a fabric substrate coated with a conductive material; applying a second mask—mirrored image of the first mask—to a second side of the fabric substrate opposite the first side; applying an etchant to the fabric substrate to remove conductive material outside of the first mask; arranging a conductive interface pad of a component carrier over an electrode defined by remaining conductive material on the fabric substrate, the component carrier including a flexible substrate and a rigid electrical component mounted to the flexible substrate, the conductive interface pad extending from a terminal of the rigid electrical component across a region of the flexible substrate; mechanically fastening the component carrier to the fabric substrate to form a garment insert including an electrical circuit; and incorporating the garment insert into the garment.
31 Citations
20 Claims
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1. A method for fabricating an article comprising:
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applying a first layer to a first side of a fabric substrate, the first side of the fabric substrate coated with a conductive material, wherein the applied first layer includes a pattern corresponding to a desired region of remaining conductive material, wherein the desired region of remaining conductive material is covered by the mask; applying a second layer to a second side of the fabric substrate opposite the first side, wherein the applied second layer covers a portion of the second side corresponding to the desired region of remaining conductive material on the first side; applying a chemical to the fabric substrate to remove conductive material not covered by the first layer; arranging a conductive portion of a component carrier over an electrode, the electrode defined by at least a portion of the remaining conductive material on the fabric substrate, the component carrier comprising a flexible substrate and a rigid electrical component mounted to the flexible substrate, the conductive portion extending from a terminal of the rigid electrical component across a region of the flexible substrate; fastening the component carrier to the fabric substrate to form an insert; forming an electrical connection between the conductive portion and the electrode to form an electrical circuit on the insert; and inserting the insert into a soft good. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. An article comprising:
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an outer layer comprising a textile; a lining comprising a textile; a circuitry layer interposed between the outer layer and the lining and comprising; a fabric substrate; a layer of conductive material coated onto a first side of the fabric substrate and selectively etched from the fabric substrate to form a portion of an electrical circuit across the fabric substrate, wherein the portion of the electrical circuit across the fabric substrate is formed by; applying a first layer to a first side of a fabric substrate, the first side of the fabric substrate coated with a conductive material, wherein the applied first layer includes a pattern corresponding to a desired region of remaining conductive material, wherein the desired region of remaining conductive material is covered by the mask; applying a second layer to a second side of the fabric substrate opposite the first side, wherein the applied second layer covers a portion of the second side corresponding to the desired region of remaining conductive material on the first side; applying a chemical to the fabric substrate to remove conductive material not covered by the first layer; and a component carrier comprising a flexible substrate, a rigid electrical component mounted to the flexible substrate, wherein the rigid electrical component includes a light-emitting diode, and a first conductive portion extending from a first terminal of the rigid electrical component, wherein the first conductive portion is coupled to the portion of the electrical circuit across the fabric substrate. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A circuitry layer configured to be sewn into an article, the circuitry layer comprising:
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a fabric substrate; a layer of conductive material coated onto a first side of the fabric substrate and selectively etched from the fabric substrate to form an electrode within an electrical circuit on the fabric substrate, wherein the selective etching includes; applying a first layer to a first side of a fabric substrate, the first side of the fabric substrate coated with a conductive material, wherein the applied first layer includes a pattern corresponding to a desired region of remaining conductive material, wherein the desired region of remaining conductive material is covered by the mask; applying a second layer to a second side of the fabric substrate opposite the first side, wherein the applied second layer covers a portion of the second side corresponding to the desired region of remaining conductive material on the first side; applying a chemical to the fabric substrate to remove conductive material not covered by the first layer; a volume of a substance comprising a conductive particulate, a polymer, and a solvent applied over the layer of conductive material at the electrode; a component carrier, comprising a flexible substrate, an electrical component mounted to the flexible substrate, and a conductive portion positioned over the flexible substrate and extending from a terminal of the electrical component, and positioned over the fabric substrate with the conductive portion in contact with the volume of the substance opposite the layer of conductive material to form an electrical circuit; and a filament passing through the fabric substrate and the component carrier and configured to constrain the fabric substrate and the component carrier against the volume of the substance. - View Dependent Claims (18, 19, 20)
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Specification