METHOD FOR MAKING ELECTRICALLY CONDUCTIVE TEXTILES AND TEXTILE SENSOR

• US 20160186366A1
• Filed: 08/14/2014
• Published: 06/30/2016
• Est. Priority Date: 08/16/2013
• Status: Active Grant

• Current Assignee: Footfalls and Heartbeats Limited
• Original Assignee: Footfalls and Heartbeats Limited
• Inventors: MCMASTER, Simon Adair
• Granted Patent: US 10,119,208 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: D04B 1/14 Other fabrics or articles characterised primarily by the use of particular thread materials
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2403/02431 with electronic components, e.g. sensors or switches
• CPC Class Codes: G01N 27/223 for determining moisture content, e.g. humidity rain detectors on vehicle windows B60S1/0825

Abstract

A method for making a textile sensor and a textile sensor can include selecting a combination of variables from the group consisting of yarn variables, stitch variables, and textile variables; and knitting an electrically conductive yarn in the textile sensor in accordance with the selected combination of variables, wherein the combination of variables is selected so as to provide a controlled amount of contact resistance in the textile sensor. The method and textile can further include a capacitive textile-sensor having at least two integrally knit capacitor plate elements and having a configuration adapted for a sensing activity. Resistance in the textile sensor can automatically calibrate to a stable baseline level after the textile sensor is applied to a body.

Claims

1. A method for making a textile sensor, comprising:

selecting a combination of variables from the group consisting of yarn variables, stitch variables, and textile variables; and

knitting an electrically conductive yarn in the textile sensor in accordance with the selected combination of variables,

wherein the combination of variables is selected so as to provide a controlled amount of contact resistance in the textile sensor.

2. The method of claim 1, wherein the selecting a combination of variables further comprises selecting an increased tex yarn count so as to provide an increased cover factor and a decreased amount of contact resistance.

3. The method of claim 1,

wherein the selecting a combination of variables further comprises selecting a filament yarn so as to provide an increased amount of contact resistance,

whereby the textile sensor is adapted to have decreased measurement sensitivity for measuring large mass or pressure differences.

4. The method of claim 1,

wherein the selecting a combination of variables further comprises selecting a staple fiber yarn so as to provide a decreased amount of contact resistance,

whereby the textile sensor is adapted to have increased measurement sensitivity for measuring small mass or pressure differences.

5. The method of claim 1, the textile sensor further comprising a capacitive textile-sensor having at least two integrally knit capacitor plate elements comprising the electrically conductive yarn and having a configuration adapted for a sensing activity.

6. The method of claim 5, wherein the configuration further comprises a selected contact resistance within the knitted capacitor plate elements.

7. The method of claim 5, wherein the capacitor plate elements each further comprise a defined yarn contact area, and wherein the selected contact resistance comprises a selected number and shape of yarn contact points within each yarn contact area.

8. The method of claim 5, wherein the configuration further comprises a selected size, shape, and position of the capacitor plate elements and a diaelectric material within the capacitive textile-sensor.

9. The method of claim 5, wherein a measure of capacitance by the capacitive textile-sensor correlates with an amount of strain in the capacitive textile-sensor.

10. The method of claim 5, wherein the capacitor plate elements are knit as a series of spaced apart, interdigitated fingers.

11. The method of claim 5, wherein the capacitor plate elements are knit into a defined area of two opposable fabric layers.

12. The method of claim 5, wherein the capacitive textile-sensor is knit in a wearable garment during fabrication of the garment.

13. The method of claim 1, wherein resistance in the textile sensor automatically calibrates to a stable baseline level after the textile sensor is applied to a body.

14. The method of claim 1, wherein resistance in the textile sensor automatically calibrates to a stable baseline level within 90 seconds after the textile sensor is applied to a person'"'"'s leg.

15. The method of claim 1, wherein resistance in the textile sensor automatically calibrates to a stable baseline level between 20-85 seconds after the textile sensor is applied to a person'"'"'s calf or ankle.

16. A textile sensor, comprising:

an electrically conductive yarn knitted in the textile sensor in accordance with a combination of variables selected from the group consisting of yarn variables, stitch variables, and textile variables,

wherein the combination of variables is selected so as to provide a controlled amount of contact resistance in the textile sensor.

17. The textile sensor of claim 16, wherein the selected combination of variables further comprises an increased tex yarn count so as to provide an increased cover factor and a decreased amount of contact resistance.

18. The textile sensor of claim 16,

wherein the selected combination of variables further comprises a filament yarn so as to provide an increased amount of contact resistance,

whereby the textile sensor is adapted to have decreased measurement sensitivity for measuring large mass or pressure differences.

19. The textile sensor of claim 16,

wherein the selected combination of variables further comprises a staple fiber yarn so as to provide a decreased amount of contact resistance,

whereby the textile sensor is adapted to have increased measurement sensitivity for measuring small mass or pressure differences.

20. The textile sensor of claim 16, further comprising a capacitive textile-sensor having at least two integrally knit capacitor plate elements comprising the electrically conductive yarn and having a configuration adapted for a sensing activity.

21. The textile sensor of claim 20, wherein the configuration further comprises a selected contact resistance within the knitted capacitor plate elements.

22. The textile sensor of claim 20, wherein the capacitor plate elements each further comprise a defined yarn contact area, and wherein the selected contact resistance comprises a selected number and shape of yarn contact points within each yarn contact area.

23. The textile sensor of claim 20, wherein the configuration further comprises a selected size, shape, and position of the capacitor plate elements and a diaelectric material within the capacitive textile-sensor.

24. The textile sensor of claim 20, wherein a measure of capacitance by the capacitive textile-sensor correlates with an amount of strain in the capacitive textile-sensor.

25. The textile sensor of claim 20, wherein the capacitor plate elements are knit as a series of spaced apart, interdigitated fingers.

26. The textile sensor of claim 20, wherein the capacitor plate elements are knit into a defined area of two opposable fabric layers.

27. The textile sensor of claim 20, wherein the capacitive textile-sensor is knit in a wearable garment during fabrication of the garment.

28. The textile sensor of claim 16, wherein resistance in the textile sensor automatically calibrates to a stable baseline level after the textile sensor is applied to a body.

29. The textile sensor of claim 16, wherein resistance in the textile sensor automatically calibrates to a stable baseline level within 90 seconds after the textile sensor is applied to a person'"'"'s leg.

30. The textile sensor of claim 16, wherein resistance in the textile sensor automatically calibrates to a stable baseline level between 20-85 seconds after the textile sensor is applied to a person'"'"'s calf or ankle.