Electrical components and circuits constructed as textiles

• US 8,669,195 B2
• Filed: 09/27/2012
• Issued: 03/11/2014
• Est. Priority Date: 02/27/2004
• Status: Active Grant

• Current Assignee: Intelligent Textiles Limited
• Original Assignee: Intelligent Textiles Limited
• Inventors: Swallow, Stanley Shigezo, Peta-Thompson, Asha
• Primary Examiner(s): Choi, Peter Y
• Application Number:
  US13/628,287
• Publication Number:
  US 20130020313A1
• Time in Patent Office: 530 Days
• Field of Search: 442/181, 442/228, 442/229, 345/173, 345/174
• US Class Current: 442/229
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 15/00 Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D10B 2101/20 Metallic fibres
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2211/04 Silk
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: D10B 2403/02431 with electronic components, e.g. sensors or switches
• CPC Class Codes: H01H 2203/0085 Layered switches integrated into garment, clothes or textile
• CPC Class Codes: H01H 2203/01 Woven wire screen
• 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 3/10 in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• CPC Class Codes: Y10T 442/30 Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3033 Including a strip or ribbon
• CPC Class Codes: Y10T 442/3382 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/339 Metal or metal-coated strand

Abstract

Electrical components are formed in a fabric during the weaving process by a series of crossing conductors in the warp and weft fibers of the fabric. Some of the crossing points provide permanent Separation of the crossing conductors, others permanent connection of the crossing conductors and others connection upon the application of pressure to the fabric. The structure provides the possibility of forming a greater range of components and more reliable component characteristics than heretofore possible.

Claims

1. A fabric having a woven construction, including in its woven construction a plurality of spaced first elongated electrically conductive filaments or fibers and a plurality of spaced second elongated electrically conductive filaments or fibers, said first elongated electrically conductive filaments or fibers being crossed by said second elongated electrically conductive filaments or fibers at a plurality of crossover points,

wherein said plurality of crossover points consists of at least one instance of a crossover point at which the first and second electrically conductive filaments or fibers are permanently biased apart and at least one instance of a crossover point at which said corresponding first and second electrically conductive filaments or fibers are permanently physically connected together,

wherein said permanently connected crossover points and said permanently biased apart crossover points bring into being at least one conductive path within said fabric that is composed of two or more contiguous segments of two or more electrically conductive filaments or fibers, the conductive path being arranged in series in a serpentine manner.

2. A fabric as claimed in claim 1, wherein the fabric includes a warp and a weft and wherein the warp includes at least one said first electrically conductive filaments or fiber and the weft includes at least one said second electrically conductive filaments or fiber.

3. A fabric as claimed in claim 1, including insulating fibers or filaments which bias the first and second electrically conductive filaments or fibers apart at said crossover points.

4. A fabric as claimed in claim 3, wherein the woven construction includes yarn and warp and/or weft floats over or under more than one yarn to effect the biasing apart of first and second electrically conductive filaments or fibers at said crossover points.

5. A fabric as claimed in claim 4, wherein the first and/or second electrically conductive filaments or fibers are subject to a warp and/or weft float over or under more than one yarn.

6. A fabric as claimed in claim 4, including a warp and a weft and insulating warp fibers neighbouring an electrically conductive filaments or fiber in the warp, wherein the neighbouring insulating warp fibers to an electrically conductive filaments or fiber in the warp are subject to a warp float over or under more than one weft yarn.

7. A fabric as claimed in claim 4, including a warp and a weft and insulating weft fibers neighbouring an electrically conductive filaments or fiber in the weft, wherein the neighbouring insulating weft fibers to an electrically conductive filaments or fiber in the weft are subject to a weft float over or under more than one warp yarn.

8. A fabric as claimed in claim 1, wherein the one or more crossover points at which the corresponding first and second electrically conductive filaments or fibers are permanently physically connected together are effected by means of a plain weave structure local to that crossover point.

9. A fabric as claimed in claim 1, wherein the two or more contiguous segments are of two or more electrically conductive filaments or fibers that exhibit differing linear resistivities.

10. A fabric as claimed in claim 1, wherein the contiguous segments of electrically conductive filaments or fibers have a length and/or number and/or linear resistivity chosen so as to constitute one or more resultant conductive paths that conform to a required electrical characteristic and/or a required value of electrical property.

11. A fabric as claimed in claim 10, wherein the electrical property is selected from the group consisting of electrical resistance, capacitance, inductance, impedance and reactance.

12. A fabric as claimed in claim 10, wherein the electrical characteristic is a heterogeneous distribution of resistance along the resultant conductive path and/or across the fabric.

13. A fabric as claimed in claim 12, wherein the fabric provides an electrical heating element that exhibits a heterogeneous distribution of heated power dissipation along the resultant conductive path and/or across the fabric.

14. A fabric having a woven construction with a warp and a weft, the fabric including:

I. several spaced elongated first electrically conductive elements included in the warp of the fabric;

II. several spaced elongated second electrically conductive elements included in the weft of the fabric, and crossing the first electrically conductive elements at several crossover points; and

III. elongated insulating elements in the warp and/or the weft of the fabric,

wherein said crossover points consist of;

A. one or more crossover points at which the first and second electrically conductive elements are permanently biased apart, the permanent biasing being effected by warp and/or weft floats of the first and/or second electrically conductive elements over or under more than one of the elongated insulating elements, and

B. one or more crossover points at which the first and second electrically conductive elements are permanently in conductive communication, the permanent conductive communication being effected by a plain weave in the warp and weft at the crossover point,

wherein the permanently biased apart crossover points and the crossover points in permanent conductive communication generate at least one conductive path within the fabric that includes two or more contiguous segments of two or more of the electrically conductive elements, the conductive path being arranged across two or more of the electrically conductive elements in series in a serpentine manner, the contiguous segments together having one or more of;

(1) a length,

(2) a number, and/or

(3) a linear resistivity,

with the conductive paths providing desired electrical characteristics.

15. The fabric of claim 14 wherein the warp includes:

a. elongated insulating elements, and

b. an elongated electrically conductive element neighboring the elongated insulating elements,

wherein the insulating elements include a warp float over or under more than one of the elements in the weft.

16. The fabric of claim 14 wherein the weft includes:

a. elongated insulating elements, and

b. an elongated electrically conductive element neighboring the elongated insulating elements,

wherein the insulating elements include a weft float over or under more than one of the elements in the warp.

17. The fabric of claim 14 wherein the two or more contiguous segments of two or more of the electrically conductive elements include electrically conductive elements having different linear resistivities.

18. The fabric of claim 14 wherein the desired electrical characteristics include one or more of:

a. resistance,

b. capacitance,

c. inductance,

d. impedance, and

e. reactance.

19. The fabric of claim 14 wherein the desired electrical characteristics include a heterogeneous distribution of resistance along one or more of:

a. the conductive path, and

b. the entire fabric.