FLEXIBLE EMBEDDED INTERCONNECTS

• US 20140170919A1
• Filed: 12/14/2012
• Published: 06/19/2014
• Est. Priority Date: 12/14/2012
• Status: Active Grant

• Current Assignee: Intel Corporation
• Original Assignee: Intel Corporation
• Inventors: Manipatruni, Sasikanth, Doyle, Brian S., Liff, Shawna M., Singh, Vivek K.
• Granted Patent: US 9,822,470 B2
• Time in Patent Office: Days
• US Class Current: 442/188
• CPC Class Codes: B21C 23/08 Making wire, bars, tubes
• CPC Class Codes: B21C 37/042 Manufacture of coated wire or bars
• CPC Class Codes: B21C 37/047 of fine wires
• CPC Class Codes: D01D 5/00 Formation of filaments, threads, or the like
• CPC Class Codes: D01D 5/34 Core-skin structure; Spinnerette packs therefor
• CPC Class Codes: D02G 3/441 Yarns or threads with antistatic, conductive or radiation-shielding properties electroconductive, anti-static or radiation-shielding filaments D01F1/09, D01F1/106; anti-static fabrics D03D15/533; conducting, insulating or anti-static layers for floor coverings D06N7/0042
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D04H 1/4266 Natural fibres not provided for in group D04H1/425
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43838 Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 3/00 Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: D10B 2401/18 including electronic components
• CPC Class Codes: Y10T 442/3057 Multiple coatings
• CPC Class Codes: Y10T 442/603 Including strand or fiber material precoated with other than free metal or alloy

Abstract

Flexible electronically functional fibers are described that allow for the placement of electronic functionality in traditional fabrics. The fibers can be interwoven with natural fibers to produce electrically functional fabrics and devices that can retain their original appearance.

Claims

1. A flexible electrically functional fiber comprising:

a core;

a first conductive layer adjacent the core;

a dielectric layer adjacent the first conductive layer;

a second conductive layer adjacent the dielectric layer; and

an insulative coating surrounding the second conductive layer, wherein the flexible electrically functional fiber has a natural bending radius of less than 2.0 mm.

4. The functional fiber of claim 1 wherein the fiber has an average diameter of less than 1 μ

m.

5. The functional fiber of claim 1 wherein the fiber has a natural bending radius of less than 1.0 mm.

7. The functional fiber of claim 1 wherein the fiber has a natural bending radius of less than 0.5 mm.

8. The functional fiber of claim 1 wherein the core comprises a textile fiber.

9. The functional fiber of claim 1 wherein the core comprises a natural fiber.

12. The functional fiber of claim 1 wherein the core comprises a polymer.

15. The functional fiber of claim 1 wherein at least one of the conductive layers has a resistance of less than 10⁻

7 Ω

·

m.

19. The functional fiber of claim 1 wherein the dielectric layer is interrupted along the length of the functional fiber.

20. The functional fiber of claim 1 comprising an input device, a power source, memory cell, a communication channel, an interconnect, a capacitor, and/or an output device.

21. The functional fiber of claim 1 comprising an input device wherein the input device comprises a piezoelectric material.

24. The functional fiber of claim 20 comprising an output device wherein the output device comprises a piezo luminescent material.

27. The functional fiber of claim 1 wherein each of the layers is less than 100 nm in thickness.

28. A woven or non-woven fabric comprising the functional fiber of claim 1.

29. A woven fabric comprising the functional fiber of claim 1 wherein the fabric comprises textile fibers.

30. A woven fabric comprising a first functional fiber as defined in claim 1 and at least a second functional fiber as defined in claim 1, wherein the second functional fiber is positioned substantially perpendicular to the first functional fiber.

32. The woven fabric of claim 28 wherein a functional fiber comprises a touch sensitive piezoelectric device.

36. A twisted pair of conductors comprising a functional fiber of claim 1.

37. A fiber comprising the twisted pair of claim 36 and a textile fiber.

79. A user interface comprising the fabric of claim 28.

2-3. -3. (canceled)

6. (canceled)

10-11. -11. (canceled)

13-14. -14. (canceled)

16-18. -18. (canceled)

22-23. -23. (canceled)

25-26. -26. (canceled)

31. (canceled)

33-35. -35. (canceled)

38-43. -43. (canceled)

44. A method of producing a flexible electrically functional fiber, the method comprising:

coating a fiber core with an electrically conductive material to form a first electrically conductive layer;

applying a dielectric material to the first electrically conductive layer to form a dielectric layer;

applying an electrically conductive material to the dielectric layer to form a second electrically conductive layer; and

applying an outer coating material to the second electrically conductive layer to produce the flexible electrically functional fiber.

46. The method of claim 44 wherein at least one of the materials is applied or coated using chemical vapor deposition or atomic layer deposition.

50. The method of claim 44 wherein the fiber core comprises a textile fiber.

53. The method of claim 44 wherein dielectric layer is applied intermittently to provide portions of dielectric layer separated by portions void of dielectric material.

65. The method of claim 44 further comprising weaving the flexible electrically functional fiber into a fabric.

66. The method of claim 65 further comprising using the fabric to produce electrically functional clothing, outerwear, footwear, uniforms or upholstery.

67. The method of claim 65 further comprising laundering the fabric without losing electrical functionality of the fabric.

45. (canceled)

47-49. -49. (canceled)

51-52. -52. (canceled)

54-64. -64. (canceled)

68. (canceled)

69. A method of producing a flexible electrically functional fiber, the method comprising:

forming a billet comprising concentric layers including a core, a first conductive layer, a dielectric layer and a second conductive layer; and

forcing the billet through a die to produce the flexible electrically functional fiber having a reduce diameter and increased the length compared to the billet.

72. The method of claim 69 wherein the flexible electrically functional fiber has a natural bending radius of less than 2.0 mm.

74. The method of claim 69 wherein the dielectric layer in the billet is interrupted by a ring of different material that is electrically active and has an inner diameter and outer diameter substantially equivalent to the inner and outer diameter of the dielectric layer in the billet.

76. The method of claim 74 wherein the different material comprises a piezo active material.

70-71. -71. (canceled)

73. (canceled)

75. (canceled)

77-78. -78. (canceled)

80-81. -81. (canceled)