Plural layer woven electronic textile, article and method

• US 20030211797A1
• Filed: 05/08/2003
• Published: 11/13/2003
• Est. Priority Date: 05/10/2002
• Status: Active Grant

• Current Assignee: Philadelphia University (Main Line Health System), Sarnoff Corporation (SRI International, Inc.)
• Original Assignee: Philadelphia University (Main Line Health System)
• Inventors: Riddle, George Herbert Needham, Hill, Ian Gregory, Trotz, Seth
• Granted Patent: US 7,144,830 B2
• Time in Patent Office: Days
• US Class Current: 442/205
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 11/00 Double or multi-ply fabrics not otherwise provided for
• CPC Class Codes: D03D 13/006 With additional leno yarn
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: H01H 2203/0085 Layered switches integrated into garment, clothes or textile
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 1/141 One or more single auxiliary printed circuits mounted on a main printed circuit, e.g. modules, adapters H05K1/142 and H05K1/147 take precedence
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/0278 Polymeric fibers
• CPC Class Codes: H05K 2201/0281 Conductive fibers
• CPC Class Codes: H05K 2201/029 Woven fibrous reinforcement or textile textile substrates H05K1/038
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: Y10T 442/2475 Coating or impregnation is electrical insulation-providing, -improving, or -increasing, or conductivity-reducing
• CPC Class Codes: Y10T 442/30 Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/3203 Multi-planar warp layers
• CPC Class Codes: Y10T 442/3211 Multi-planar weft layers
• CPC Class Codes: Y10T 442/3472 Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/3976 Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

A woven article having plural weave layers comprises a plurality of electrically insulating and/or electrically conductive yarn in the warp and a plurality of electrically insulating and/or electrically conductive yarn in the weft interwoven with the yarn in the warp. An electrical function is provided by one or more circuit carriers disposed in cavities in the plural layer woven article and/or one or more functional yarn in the warp and/or the weft, wherein the circuit carrier and/or functional yarn include an electrical contact for connecting to the electrically conductive yarn in the warp and/or weft.

Claims

1. A multilayer woven article having an electronic function woven therein comprising:

warp yarn and weft yarn interwoven in a multilayer weave having plural layers defining at least one cavity therebetween;

at least one electrically conductive yarn disposed in the warp and/or in the weft and having a portion thereof in one of the plural layers defining the at least one cavity; and

a circuit carrier disposed in the cavity and having at least one exposed electrical contact in electrical connection with said at least one electrically conductive yarn, said circuit carrier including at least one electronic device for performing a function.

2. The multilayer woven article of claim 1 further comprising at least one functional yarn disposed in one of the warp and the weft, said functional yarn comprising:

an elongate substrate including at least one electrical conductor disposed thereon, and

at least one electronic device on said elongate substrate, wherein the at least one electrical conductor on said elongate substrate electrically connects said electronic device of said functional yarn and said at least one electrically conductive yarn.

3. The multilayer woven article of claim 1 wherein said at least one electrically conductive yarn and said at least one electrical contact of said circuit carrier are in electrical contact at a location where said at least one electrically conductive yarn crosses the contact of said circuit carrier in the woven article without a mechanical attaching thereof at that location.

4. The multilayer woven article of claim 1 wherein said at least one electronic device of said circuit carrier is addressable by passive matrix addressing, active matrix addressing, serial addressing, parallel addressing, scanned addressing, active addressing, block addressing, and/or individual addressing communicated via said at least one electrically conductive yarn and the at least one exposed electrical contact of said circuit carrier.

5. The multilayer woven article of claim 1:

wherein said at least one electrically conductive yarn includes electrically conductive yarn for providing electrical power to said electronic device of said circuit carrier via the at least one exposed electrical contact thereof; and

/or

wherein said at least one electrically conductive yarn includes electrically conductive yarn for providing electrical power to said electronic device of said circuit carrier via the at least one exposed electrical contact thereof, and further includes a signal and/or data conductor for controlling and/or activating said at least one electronic device via the at least one exposed electrical contact of said circuit carrier.

6. The multilayer woven article of claim 1 wherein the at least one exposed electrical contact of said circuit carrier is elongate and is aligned with an electrically conductive yarn in the warp and wherein a second exposed electrical contact of said circuit carrier is elongate and is aligned with an electrically conductive yarn in the weft.

7. The multilayer woven article of claim 1 wherein said at least one electronic device includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a fuel cell, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

8. The multilayer woven article of claim 1 embodied in a fabric, a textile, a consumer article, a professional article, a commercial article, a government article, a military article, programmable alpha-numeric signage, a traffic warning sign, an advertising sign, a window sign, a banner, a portable sign, a garment, an article of clothing, an article and/or garment for a baby and/or an infant, a safety-wear bib, a vest, a safety garment, a personal flotation device, life saving apparatus, footwear, a blanket, a medical device, a light blanket, a warming blanket, a sensing blanket, apparatus and/or equipment for sport, sports wear, a uniform, a toy, an entertainment device, truck signage, vehicle signage, a construction and/or work area sign, a directional sign, lighting, emergency lighting, a lighting panel, a decorative light, an accent light, a reading light, lighting for a tent, tarp, canvas and/or umbrella, display lighting, a sensor fabric, an environmental and/or chemical and/or biological agent sensor array, camouflage, a parachute, a light sensing array, and/or an imaging array.

9. A multilayer woven article having a warp and a weft comprising:

a plurality of electrically insulating and/or uninsulated electrically conductive yarn in the warp for defining plural layers;

a plurality of electrically insulating and/or uninsulated electrically conductive yarn in the weft interwoven in a multilayer weave with said plurality of electrically insulating and/or electrically conductive yarn in the warp for defining a pocket between first and second woven layers thereof;

wherein at least one uninsulated electrically conductive yarn in the warp is in the first woven layer defining the pocket and at least one uninsulated electrically conductive yarn in the weft is in the second woven layer defining the pocket; and

a circuit carrier disposed in the pocket and having two opposing broad exterior surfaces in physical contact with the first and second woven layers, said circuit carrier having at least a first electrical contact on a first of the exterior surfaces and having at least a second electrical contact on a second of the exterior surfaces, said circuit carrier including at least one electronic device electrically coupled to said first and second electrical contacts,

wherein said first electrical contact is in electrical connection with the at least one uninsulated electrically conductive yarn in the first woven layer and said second electrical contact is in electrical connection with the at least one uninsulated electrically conductive yarn in the second woven layer.

10. The multilayer woven article of claim 9 wherein said first electrical contact includes a first elongate electrical contact disposed in a first orientation on the first of the exterior surfaces and wherein said second electrical contact includes a second elongate electrical contact disposed in a second orientation on the second of the exterior surfaces, wherein the second orientation is transverse to the first orientation.

11. The multilayer woven article of claim 9:

wherein said at least one uninsulated electrically conductive yarn in the first woven layer and said first electrical contact of said circuit carrier are in electrical contact at a crossing thereof without a mechanical attaching thereof at that crossing, and/or

wherein said at least one uninsulated electrically conductive yarn in the second woven layer and said second electrical contact of said circuit carrier are in electrical contact at a crossing thereof without a mechanical attaching thereof at that crossing.

12. The multilayer woven article of claim 9 wherein said at least one electronic device of said circuit carrier is addressable by passive matrix addressing, active matrix addressing, serial addressing, parallel addressing, scanned addressing, active addressing, block addressing, and/or individual addressing communicated via said at least one uninsulated electrically conductive yarn and the first and/or second electrical contact of said circuit carrier.

13. The multilayer woven article of claim 9 further comprising at least one functional yarn disposed in one of the warp and the weft adjacent an electrically insulating yarn thereof, said functional yarn comprising:

an elongate substrate including at least one electrical conductor disposed thereon,

at least one electronic device on said elongate substrate,

wherein the at least one electrical conductor provides directly and/or indirectly an electrical contact for connecting to said electronic device on said elongate substrate.

14. The multilayer woven article of claim 12 wherein said at least one functional yarn is interwoven to cross at least one uninsulated electrically conductive yarn and to connect thereto at the crossing,

wherein the at least one electrical conductor of said functional yarn provides indirectly via said at least one uninsulated electrically conductive yarn an electrical connection to said electronic device of said functional yarn, and/or

wherein the at least one electrical conductor of said functional yarn is in electrical contact with an uninsulated electrically conductive yarn at a location where said functional yarn crosses said uninsulated electrically conductive yarn in the woven article without a mechanical attaching of said functional yarn and said uninsulated electrically conductive yarn at said location.

15. The multilayer woven article of claim 9 wherein said at least one electronic device includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a fuel cell, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

16. The multilayer woven article of claim 9 embodied in a fabric, a textile, a consumer article, a professional article, a commercial article, a government article, a military article, programmable alpha-numeric signage, a traffic warning sign, an advertising sign, a window sign, a banner, a portable sign, a garment, an article of clothing, an article and/or garment for a baby and/or an infant, a safety-wear bib, a vest, a safety garment, a personal flotation device, life saving apparatus, footwear, a blanket, a medical device, a light blanket, a warming blanket, a sensing blanket, apparatus and/or equipment for sport, sports wear, a uniform, a toy, an entertainment device, truck signage, vehicle signage, a construction and/or work area sign, a directional sign, lighting, emergency lighting, a lighting panel, a decorative light, an accent light, a reading light, lighting for a tent, tarp, canvas and/or umbrella, display lighting, a sensor fabric, an environmental and/or chemical and/or biological agent sensor array, camouflage, a parachute, a light sensing array, and/or an imaging array.

17. A multilayer woven article having a warp and a weft, and defining an electrical circuit, said multilayer woven article comprising:

a plurality of electrically insulating yarn and uninsulated electrically conductive yarn defining plural layers in the warp;

a plurality of electrically insulating yarn and uninsulated electrically conductive yarn in the weft interwoven in a multilayer weave with said plurality of electrically insulating yarn and uninsulated electrically conductive yarn in plural layers in the warp;

wherein an uninsulated electrically conductive yarn in the warp crossing an uninsulated electrically conductive yarn in the weft makes electrical connection therewith at the crossing thereof; and

at least one uninsulated electrically conductive yarn in the warp and/or in the weft woven into at least first and second ones of the plural layers for crossing at least one uninsulated electrically conductive yarn in the other of the warp and/or weft without making electrical contact therewith;

whereby a woven multilayer article is provided wherein conductors disposed in transverse orientations are woven so as to connect at certain crossings and to not connect at other crossings to define an electrical circuit.

18. The multilayer woven article of claim 17 wherein said plurality of electrically insulating yarn and/or electrically conductive yarn includes at least one electrically conductive yarn in the warp in electrical contact with at least one electrically conductive yarn in the weft at a crossing thereof without mechanically attaching the electrically conductive yarn thereat.

19. The multilayer woven article of claim 17 further comprising:

at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn thereof, wherein the functional yarn comprises an elongate substrate including at least one electrical conductor disposed thereon and at least one electronic device on the elongate substrate and electrically connected to the at least one electrical conductor thereon,

wherein the at least one electrical conductor and at least one uninsulated electrically conductive yarn in the other of the warp and the weft cross for providing an electrical connection to the electronic device.

20. The multilayer woven article of claim 17 further comprising electrically insulating yarn woven in a third layer intermediate the first and second ones of the plural layers for interposing an insulating layer between uninsulated electrically conductive yarn in the first and second ones of the plural layers.

21. A circuit carrier comprising:

an electrical circuit substrate having two substantially parallel planar portions defining two opposing broad exterior surfaces and an internal cavity, said electrical circuit substrate having at least a first elongate electrical contact disposed in a first orientation on a first of the exterior surfaces and having at least a second elongate electrical contact disposed in a second orientation on a second of the exterior surfaces, wherein the second orientation is transverse to the first orientation;

at least one electronic device disposed in the internal cavity between the two substantially parallel planar portions of said electrical circuit substrate, wherein said at least one electronic device is electrically coupled to said first and second elongate electrical contacts; and

an encapsulant substantially filling the internal cavity and encapsulating said at least one electronic device therein.

22. The circuit carrier of claim 21 wherein said electrical circuit substrate is a unitary electrical circuit substrate that is folded to define the two substantially parallel planar portions;

wherein the at least a first elongate electrical contact disposed on the first of the exterior surfaces and the at least a second elongate electrical contact disposed on the second of the exterior surfaces are disposed on a first surface of said unitary electrical circuit substrate; and

wherein said at least one electronic device is mounted to a second surface of said unitary electronic circuit substrate.

23. The circuit carrier of claim 21 wherein said at least one electronic device includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a fuel cell, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

24. A method for weaving a multilayer fabric and/or a textile article having a warp and a weft comprising:

providing a plurality of electrically insulating yarn and/or electrically conductive yarn defining plural layers in the warp;

weaving a plurality of electrically insulating yarn and/or electrically conductive yarn in the weft in a multilayer weave with said plurality of electrically insulating yarn and/or electrically conductive yarn in plural layers in the warp to define at least one cavity between two layers thereof;

wherein at least one electrically conductive yarn in the warp and/or in the weft is woven in a layer defining the at least one cavity; and

placing a circuit carrier in the at least one cavity, wherein the circuit carrier includes exposed electrical contacts providing electrical connection between an electronic device in the circuit carrier and the at least one electrically conductive yarn in the warp and/or the weft that is woven in the layer defining the at least one cavity.

25. The method of claim 24 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn includes controlling a tightness of the weave and/or a density of yarn for maintaining at least one electrically conductive yarn in the warp in electrical contact with at least one electrically conductive yarn in the weft at a crossing thereof without mechanically attaching the electrically conductive yarn thereat.

26. The method of claim 24 further comprising:

weaving at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn thereof, wherein the functional yarn comprises an elongate substrate including at least one electrical conductor disposed thereon and at least one electronic device on the elongate substrate and electrically connected to the at least one electrical conductor thereon,

wherein the at least one electrical conductor and at least one electrically conductive yarn in the other of the warp and the weft cross for providing an electrical connection to the electronic device.

27. The method of claim 26 wherein the at least one functional yarn is in the weft and includes at least one registration indicia, further comprising:

sensing the at least one registration indicia of the at least one functional yarn during said weaving at least one functional yarn; and

registering the at least one functional yarn in the weft in response to the sensed at least one registration indicia.

28. The method of claim 26 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn and said weaving at least one functional yarn include controlling a tightness of the weave and/or a density of yarn for maintaining the at least one electrical conductor of the functional yarn in electrical contact with an electrically conductive yarn at a location where the functional yarn crosses the electrically conductive yarn in the woven fabric and/or article without mechanically attaching the functional yarn and the electrically conductive yarn at that location.

29. The method of claim 24 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn in the weft in a multilayer weave with said plurality of electrically insulating yarn and/or electrically conductive yarn in plural layers in the warp to define at least one cavity between two layers thereof comprises:

partially weaving the at least one cavity;

then said placing a circuit carrier in the at least one cavity; and

then further weaving the at least one cavity to enclose the circuit carrier therein.

30. A method for weaving a multilayer fabric and/or a textile electrical circuit article having a warp and a weft comprising:

providing a plurality of electrically insulating yarn and uninsulated electrically conductive yarn defining plural layers in the warp;

weaving a plurality of electrically insulating yarn and uninsulated electrically conductive yarn in the weft in a multilayer weave with said plurality of electrically insulating yarn and uninsulated electrically conductive yarn in plural layers in the warp;

wherein an uninsulated electrically conductive yarn in the warp crossing an uninsulated electrically conductive yarn in the weft makes electrical connection therewith at the crossing thereof; and

weaving at least one uninsulated electrically conductive yarn in the warp and/or in the weft into at least first and second ones of the plural layers for crossing at least one uninsulated electrically conductive yarn in the other of the warp and/or weft without making electrical contact therewith;

whereby a woven multilayer electrical circuit article is provided wherein conductors disposed in transverse orientations are woven so as to connect at certain crossings and to not connect at other crossings.

31. The method of claim 30 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn includes controlling a tightness of the weave and/or a density of yarn for maintaining at least one electrically conductive yarn in the warp in electrical contact with at least one electrically conductive yarn in the weft at a crossing thereof without mechanically attaching the electrically conductive yarn thereat.

32. The method of claim 30 further comprising:

weaving at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn thereof, wherein the functional yarn comprises an elongate substrate including at least one electrical conductor disposed thereon and at least one electronic device on the elongate substrate and electrically connected to the at least one electrical conductor thereon,

wherein the at least one electrical conductor and at least one electrically conductive yarn in the other of the warp and the weft cross for providing an electrical connection to the electronic device.

33. The method of claim 32 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn and said weaving at least one functional yarn include controlling a tightness of the weave and/or a density of yarn for maintaining the at least one electrical conductor of the functional yarn in electrical contact with an electrically conductive yarn at a location where the functional yarn crosses the electrically conductive yarn in the woven fabric and/or article without mechanically attaching the functional yarn and the electrically conductive yarn at that location.