METHODS OF MAKING GARMENTS HAVING STRETCHABLE AND CONDUCTIVE INK

• US 20140318699A1
• Filed: 07/14/2014
• Published: 10/30/2014
• Est. Priority Date: 09/11/2012
• Status: Active Grant

• Current Assignee: Life Company Limited (Aiful Corporation)
• Original Assignee: Andrea Aliverti
• Inventors: LONGINOTTI-BUITONI, Gianluigi, ALIVERTI, Andrea
• Granted Patent: US 8,945,328 B2
• Time in Patent Office: Days
• US Class Current: 156/247
• CPC Class Codes: A41D 1/002 adapted to accommodate electronic equipment patients' garments for medical monitoring A41D13/1281; luminous ornaments A41D27/085
• CPC Class Codes: A41D 13/1281 with incorporated means for medical monitoring
• CPC Class Codes: A41D 27/00 Details of garments or of their making buttons, pins, buckles, slide fasteners or the like A44B
• CPC Class Codes: A41H 43/04 Joining garment parts or blanks by gluing or welding mending garments by adhesives or adhesive patches A41H27/00 ; Gluing presses
• CPC Class Codes: A61B 2505/09 Rehabilitation or training
• CPC Class Codes: A61B 2560/0204 of power management
• CPC Class Codes: A61B 2562/0247 Pressure sensors
• CPC Class Codes: A61B 2562/0257 Proximity sensors
• CPC Class Codes: A61B 2562/029 Humidity sensors
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 5/0002 Remote monitoring of patients using telemetry, e.g. transmission of vital signals via a communication network A61B5/07 takes precedence; transmission systems for measured values G08C; transmission H04B; transmission of digital information H04L; wireless communication networks H04W
• CPC Class Codes: A61B 5/0022 Monitoring a patient using a global network, e.g. telephone networks, internet
• CPC Class Codes: A61B 5/02055 Simultaneously evaluating both cardiovascular condition and temperature
• CPC Class Codes: A61B 5/024 Detecting, measuring or recording pulse rate or heart rate A61B5/0205, A61B5/021 take precedence
• CPC Class Codes: A61B 5/1112 Global tracking of patients, e.g. by using GPS
• CPC Class Codes: A61B 5/1116 Determining posture transitions
• CPC Class Codes: A61B 5/1135 by monitoring thoracic expansion
• CPC Class Codes: A61B 5/14517 for sweat
• CPC Class Codes: A61B 5/14532 for measuring glucose, e.g. by tissue impedance measurement
• CPC Class Codes: A61B 5/14539 for measuring pH
• CPC Class Codes: A61B 5/282 : Holders for multiple electrodes for introduction into the body A61B5/287
• CPC Class Codes: A61B 5/389 : Electromyography [EMG]
• CPC Class Codes: A61B 5/4806 : Sleep evaluation A61B5/4821 takes precedence; devices for inducing sleep A61M21/02
• CPC Class Codes: A61B 5/6804 : Garments; Clothes
• CPC Class Codes: A61B 5/6805 : Vests
• CPC Class Codes: A61B 5/7278 : Artificial waveform generation or derivation, e.g. synthesising signals from measured signals A61B5/327 takes precedence
• CPC Class Codes: A61B 5/7405 : using sound
• CPC Class Codes: A61B 5/743 : Displaying an image simultaneously with additional graphical information, e.g. symbols, charts, function plots
• CPC Class Codes: A61B 5/7455 : characterised by tactile indication, e.g. vibration or electrical stimulation
• CPC Class Codes: A61B 5/7475 : User input or interface means, e.g. keyboard, pointing device, joystick
• CPC Class Codes: D06M 11/74 : with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: D06M 11/83 : with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
• CPC Class Codes: D06M 15/263 : of unsaturated carboxylic acids; Salts or esters thereof
• CPC Class Codes: D06M 15/564 : Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
• CPC Class Codes: D06M 23/08 : Processes in which the treating agent is applied in powder or granular form adhesives for multi-layer textile fabrics D06M17/00
• CPC Class Codes: D06M 23/16 : Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
• CPC Class Codes: D06N 2209/041 : Conductive
• CPC Class Codes: D06N 2211/10 : Clothing
• CPC Class Codes: D06N 3/0063 : Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• CPC Class Codes: D06N 3/042 : Acrylic polymers D06N3/045 takes precedence
• CPC Class Codes: D06P 1/44 : using insoluble pigments or auxiliary substances, e.g. binders
• CPC Class Codes: D06P 1/5257 : (Meth)acrylic acid
• CPC Class Codes: D06P 1/5285 : Polyurethanes; Polyurea; Polyguanides
• CPC Class Codes: D06P 5/08 : macromolecular
• CPC Class Codes: D10B 2401/16 : antistatic; conductive
• CPC Class Codes: D10B 2501/00 : Wearing apparel
• CPC Class Codes: G06F 1/163 : Wearable computers, e.g. on a belt
• CPC Class Codes: G16H 40/67 : for remote operation
• CPC Class Codes: G16Z 99/00 : Subject matter not provided for in other main groups of this subclass
• CPC Class Codes: H04R 2201/023 : Transducers incorporated in garment, rucksacks or the like
• CPC Class Codes: H05K 1/0283 : Stretchable printed circuits
• CPC Class Codes: H05K 1/038 : Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 1/092 : Dispersed materials, e.g. conductive pastes or inks
• CPC Class Codes: H05K 1/095 : for polymer thick films, i.e. having a permanent organic polymeric binder
• CPC Class Codes: H05K 2201/0323 : Carbon
• CPC Class Codes: H05K 2201/09263 : Meander
• CPC Class Codes: H05K 2201/10151 : Sensor
• CPC Class Codes: H05K 3/361 : Assembling flexible printed circuits with other printed circuits

Abstract

Methods of forming garments having one or more stretchable conductive ink patterns. Described herein are method of making garments (including compression garments) having one or more highly stretchable conductive ink pattern formed of a composite of an insulative adhesive, a conductive ink, and an intermediate gradient zone between the adhesive and conductive ink. The conductive ink typically includes between about 40-60% conductive particles, between about 30-50% binder; between about 3-7% solvent; and between about 3-7% thickener. The stretchable conductive ink patterns may be stretched more than twice their length without breaking or rupturing.

Claims

1. A method of making a wearable electronics garment, the method comprising:

placing a transfer substrate comprising a stretchable conductive ink pattern against a compression fabric, wherein the conductive ink pattern comprises;

a layer of conductive ink having;

between about 40-60% conductive particles;

a layer of an elastic adhesive; and

a gradient region between the conductive ink and the adhesive, the gradient region comprising a nonhomogeneous mixture of the conductive ink and the adhesive wherein the concentration of conductive ink decreases from a region closer to the layer of conductive ink to the layer of elastic adhesive; and

transferring the conductive ink pattern from the transfer substrate to the compression fabric.

2. The method of claim 1, wherein the layer of conductive ink comprises between about 40-60% conductive particles, between about 30-50% binder;

between about 3-7% solvent; and

between about 3-7% thickener.

3. The method of claim 1, further comprising peeling the transfer substrate off of the conductive ink pattern.

4. The method of claim 1, wherein the transfer substrate comprises a polyurethane substrate.

5. The method of claim 1, further comprising attaching a conductive thread to the compression fabric, wherein one end of the conductive thread is electrically connected to the conductive ink pattern.

6. The method of claim 1, wherein the transfer substrate further comprises a conductive thread in electrical communication with the conductive ink pattern.

7. The method of claim 1, wherein transferring comprises applying heat to transfer the conductive ink pattern.

8. The method of claim 1, wherein transferring comprises applying heat from about 130°

C. to about 300°

C. to transfer the conductive ink pattern to the compression fabric.

9. The method of claim 1, wherein transferring comprises transferring the conductive ink pattern from the transfer substrate to the compression fabric.

10. The method of claim 1, wherein the conductive particles comprise particles of one or more of:

carbon black, graphene, graphite, silver metal powder, copper metal powder, or iron metal powder.

11. The method of claim 1, further comprising printing the conductive ink pattern on the transfer substrate before placing on the compression fabric.

12. The method of claim 1, further comprising printing the conductive ink pattern on the transfer substrate by:

printing the conductive ink onto the substrate in a first pattern;

printing the adhesive onto the substrate over the first pattern; and

forming the gradient region between the conductive ink and the adhesive.

14. The method of claim 11, wherein the substrate comprises a transfer substrate.

15. The method of claim 11, wherein the substrate comprises a compression fabric.

16. The method of claim 11, wherein the conductive ink comprises between about 40-60% conductive particles, between about 30-50% binder;

between about 3-7% solvent; and

between about 3-7% thickener.

17. The method of claim 11, wherein printing comprises placing a screen having openings configured as a first pattern onto the substrate and spreading the adhesive over the screen.

18. The method of claim 11, wherein the conductive ink has a viscosity of between about 60 Poise and 200 Poise.

19. The method of claim 11, wherein printing comprises spraying the adhesive onto the compression fabric.

20. The method of claim 11, wherein forming the gradient region comprises printing the conductive ink onto the adhesive while the adhesive is sufficiently fluid to allow diffusion of the conductive ink into an upper region of the adhesive.

22. The method of claim 19, wherein printing the conductive ink comprises printing between 3 and 20 layers of conductive ink.

23. The method of claim 19, wherein the conductive ink is printed so that the conductive ink does not directly contact the compression fabric.

24. The method of claim 19, further comprising printing an insulating resin over part of the conductive ink.

25. The method of claim 19, wherein printing the adhesive comprises placing a screen having openings configured as the first pattern onto the compression fabric and spreading the adhesive over the screen.

26. The method of claim 19, wherein printing the conductive ink comprises placing a screen having openings matching at least a portion of the first pattern onto the compression fabric and spreading the conductive ink.

27. The method of claim 19, wherein the conductive ink has a viscosity of between about 60 Poise and about 200 Poise.

28. The method of claim 19, wherein printing the conductive ink comprises printing a conductive ink having:

between about 40-60% conductive particles, between about 30-50% binder;

between about 3-7% solvent; and

between about 3-7% thickener.

29. The method of claim 19, wherein printing the adhesive onto a compression fabric comprises spraying the adhesive onto the compression fabric.

30. The method of claim 19, wherein printing the conductive ink comprises spraying the conductive ink onto the first pattern.

31. The method of claim 19, wherein forming the gradient region comprises printing the conductive ink onto the adhesive while the adhesive is sufficiently fluid to allow diffusion of the conductive ink into an upper region of the adhesive.

13. A method of making a wearable electronics garment, the method comprising:

printing a pattern of conductive ink and an elastic adhesive onto a substrate such that the conductive ink is substantially co-extensive with the adhesive, wherein the conductive ink comprises between about 40% and about 60% of conductive particles; and

forming a gradient region between the conductive ink and the adhesive, the gradient region comprising a nonhomogeneous mixture of the conductive ink and the adhesive wherein the concentration of conductive ink in the gradient region decreases from a region closer to the layer of conductive ink to the layer of elastic adhesive.

21. A method of making a wearable electronics garment, the method comprising:

printing an adhesive onto a compression fabric in a first pattern, wherein the adhesive is elastic when dry;

printing a conductive ink onto the first pattern; and

forming a gradient region between the conductive ink and the adhesive, the gradient region comprising a nonhomogeneous mixture of the conductive ink and the adhesive wherein the concentration of conductive ink in the gradient region decreases from a region closer to the layer of conductive ink to the layer of elastic adhesive.