Methods and systems for selectively connecting and disconnecting conductors in a fabric

• US 20060037686A1
• Filed: 11/19/2004
• Published: 02/23/2006
• Est. Priority Date: 01/08/2002
• Status: Active Grant

• Current Assignee: North Carolina State University (University of North Carolina System)
• Original Assignee: North Carolina State University (University of North Carolina System)
• Inventors: Dhawan, Anuj, Muth, John, Ghosh, Tushar Kanti, Seyam, Abdelfattah
• Granted Patent: US 7,329,323 B2
• Time in Patent Office: Days
• US Class Current: 156/49
• CPC Class Codes: B01D 2239/0208 Single-component fibres
• CPC Class Codes: B01D 2239/0216 Bicomponent or multicomponent fibres
• CPC Class Codes: B01D 2239/0241 comprising electrically conductive fibres or particles
• CPC Class Codes: B01D 2239/0636 Two or more types of fibres present in the filter material
• CPC Class Codes: B01D 2239/069 Special geometry of layers
• CPC Class Codes: B01D 2239/086 Binders between particles or fibres
• CPC Class Codes: B01D 39/083 of organic material
• CPC Class Codes: B01D 39/086 of inorganic material
• CPC Class Codes: H05K 1/0289 having a matrix lay-out, i.e. having selectively interconnectable sets of X-conductors and Y-conductors in different planes
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 7/06 on insulating boards , e.g. wiring harnesses for printed circuits H05K1/18, H05K3/30
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 442/339 Metal or metal-coated strand
• 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.]
• CPC Class Codes: Y10T 442/475 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/655 Metal or metal-coated strand or fiber material
• CPC Class Codes: Y10T 442/696 Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Abstract

Methods and systems for selectively connecting and disconnecting conductors in a fabric are disclosed. First and second conductors are integrated into a fabric such that the conductors intersect at a crossover point. The conductors are bonded to each other at the crossover point to improve AC and DC characteristics. Disconnect areas may be provided near the crossover point to allow selective disconnection of the conductors from the crossover point.

Claims

1. A method for interconnecting and disconnecting elongated conductors in a fabric, the method comprising:

(a) interlocking first and second elongated conductors in a fabric such that the first and second conductors intersect at a cross-over point;

(b) applying at least one of heat and electrical energy to the first and second elongated conductors to bond the first and second conductors at the cross-over point and thereby reduce electrical resistance at the cross-over point;

(c) providing disconnect areas in at least one of the first and second elongated conductors; and

(d) selectively disconnecting the elongated conductors at the disconnect areas to form a desired electric circuit.

2. The method of claim 1 wherein interlocking first and second conductors in a fabric comprises weaving first and second metallic fibers into the fabric.

3. The method of claim 1 wherein interlocking first and second conductors in a fabric comprises weaving first and second twisted pair conductors into the fabric.

4. The method of claim 1 wherein interlocking first and second conductors in a fabric includes weaving first and second coaxial conductors into the fabric.

5. The method of claim 1 wherein interlocking first and second conductors in a fabric includes weaving first and second conductive polymer fibers into the fabric.

6. The method of claim 1 wherein interlocking first and second conductors in a fabric includes weaving the first conductor into the fabric as a warp yarn and weaving the second conductor into the fabric as a weft yarn.

7. The method of claim 1 wherein interlocking first and second conductors in a fabric comprises knitting first and second conductors into a fabric.

8. The method of claim 1 wherein applying at least one of heat and electrical energy to the first and second conductors comprises resistance welding the first and second conductors.

9. The method of claim 8 wherein resistance welding the first and second conductors includes applying parallel probes to the cross-over point and applying an electric current to the crossover point through the probes.

10. The method of claim 8 wherein resistance welding the first and second conductors includes applying a conductive loop to the cross-over point and applying an electric current to the conductive loop.

11. The method of claim 8 wherein resistance welding the first and second conductors includes grounding at least one of the first and second conductive fibers using a first probe located on a first side of the first and second conductors, applying a second probe to the cross-over point on a second side of the first and second conductors, and applying an electric current to the cross-over point through the second probe.

12. The method of claim 1 wherein applying at least one of heat and electrical energy to the first and second conductors includes laser welding the first and second conductors.

13. The method of claim 1 wherein applying at least one of heat and electrical energy to the first and second conductors includes ultrasonically welding the first and second conductors.

14. The method of claim 1 wherein applying at least one of heat and electrical energy to the first and second conductors includes applying a conductive adhesive or epoxy to the first and second conductors.

15. The method of claim 1 wherein providing disconnect areas comprises providing floats in at least one of the first and second conductors and wherein selectively disconnecting the first and second conductors includes selectively cutting the floats.

16. The method of claim 1 wherein providing disconnect areas comprises incorporating switches into at least one of the first and second conductors and wherein selectively disconnecting the first and second conductors includes selectively opening or closing the switches.

17. The method of claim 1 wherein the bonding and disconnecting steps are both achieved simultaneously using parallel probe resistance welding.

18. The method of claim 1 comprising a fabric made in accordance therewith.

19. A method for connecting elongated conductive fibers in a fabric, the method comprising:

(a) interlocking first and second elongated conductors in a fabric such that the conductors intersect at a cross-over point; and

(b) applying at least one of heat and electrical energy to the elongated conductors and bonding the conductors at the cross-over point, thereby reducing electrical resistance at the cross-over point.

20. The method of claim 19 wherein interlocking first and second conductors in a fabric comprises weaving first and second metallic fibers into the fabric.

21. The method of claim 19 wherein interlocking first and second conductors in a fabric comprises weaving first and second twisted pair conductors into the fabric.

22. The method of claim 19 wherein interlocking first and second conductors in a fabric includes weaving first and second coaxial conductors into the fabric.

23. The method of claim 19 wherein interlocking first and second conductors in a fabric includes weaving first and second conductive polymer fibers into the fabric.

24. The method of claim 19 wherein interlocking first and second conductors in a fabric includes weaving the first conductor into the fabric as a warp yarn and weaving the second conductor into the fabric as a weft yarn.

25. The method of claim 19 wherein interlocking first and second conductors in a fabric comprises knitting the first and second conductors into the fabric.

26. The method of claim 19 wherein applying at least one of heat and electrical energy to the first and second conductors comprises resistance welding the first and second conductors.

27. The method of claim 26 wherein resistance welding the first and second conductors includes applying parallel probes to the cross-over point and applying an electric current to the crossover point through the probes.

28. The method of claim 26 wherein resistance welding the first and second conductors includes applying a conductive loop to the cross-over point and applying an electric current to the conductive loop.

29. The method of claim 26 wherein resistance welding the first and second conductors includes grounding at least one of the first and second conductive fibers using a first probe located on a first side of the first and second conductors, applying a second probe to the crossover point on a second side of the first and second conductors, and applying an electric current to the cross-over point through the second probe.

30. The method of claim 19 wherein applying at least one of heat and electrical energy to the first and second conductors includes laser welding the first and second conductors.

31. The method of claim 19 wherein applying at least one of heat and electrical energy to the first and second conductors includes ultrasonically welding the first and second conductors.

32. The method of claim 19 wherein applying at least one of heat and electrical energy includes simultaneously connecting and disconnecting the conductors at the crossover point using parallel probe resistance welding.

33. The method of claim 19 wherein applying at least one of heat and electrical energy to the first and second conductors includes applying a conductive adhesive or epoxy to the first and second conductors.