Functional textile structures

• US 8,709,185 B2
• Filed: 12/30/2008
• Issued: 04/29/2014
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Textronics Incorporated (Adidas AG)
• Inventors: Hassonjee, Qaizar N., Burr, Stacey B.
• Primary Examiner(s): DODDS, SCOTT
• Application Number:
  US12/345,711
• Publication Number:
  US 20090120560A1
• Time in Patent Office: 1,946 Days
• Field of Search: 156/229, 156/66, 156/92, 156/93, 156/196, 156/227, 156/244.18, 156/252, 156/46, 156/176, 156/178, 156/179, 156/226, 428/12, 428/59, 428/92, 428/93, 428122-123, 428131-137, 428/139, 428/175, 428182-184, 428/185, 428/193, 428/221, 428/914, 428/929, 428/113, 428/297.7, 428/298.1, 428/298.7, 428/299.1, 428/299.4
• US Class Current: 156/179
• CPC Class Codes: A41D 31/265 using layered materials
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2437/00 Clothing
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/342 heaters used in textiles
• CPC Class Codes: H05K 1/00 Printed circuits
• CPC Class Codes: H05K 9/009 comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1049 Folding only
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face
• CPC Class Codes: Y10T 29/49947 by applying separate fastener
• CPC Class Codes: Y10T 428/24 : Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24008 : including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/2419 : Fold at edge
• CPC Class Codes: Y10T 428/24207 : with strand[s] or strand-portion[s] between layers [e.g., upholstery trim, etc.]
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24281 : Struck out portion type
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24306 : Diamond or hexagonal
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24347 : From both sides
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249922 : Embodying intertwined or helical component[s]
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3016 : Including a preformed layer other than the elastic woven fabric [e.g., fabric or film or foil or sheet layer, etc.]
• CPC Class Codes: Y10T 442/3024 : Including elastic strand or strip
• CPC Class Codes: Y10T 442/339 : Metal or metal-coated strand
• CPC Class Codes: Y10T 442/40 : Knit fabric [i.e., knit strand or strip material]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/601 : Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/602 : Nonwoven fabric comprises an elastic strand or fiber material
• CPC Class Codes: Y10T 442/655 : Metal or metal-coated strand or fiber material

Abstract

The invention provides a functional laminate composite fabric which is robust, laundry-durable and adaptable for securing about any three dimensional body, and a method for forming such fabric. The functional laminate fabric is provided with at least one functional element which can conduct electricity, conduct light, provide electromagnetic fields or provide shielding from electromagnetic fields. The functional laminate may include vias through which the functional element may be exposed. Generally, the functional laminate fabric is sufficiently robust for incorporation into garments and for applications in so-called wearable electronics.

Claims

1. A method for preparing a functional laminate with a substantially flat appearance, comprising:

providing a length of a first piece of fabric having a first surface and a second surface;

perforating the first piece of fabric to form one or more predetermined via openings therethrough, each said via opening having a length and a width;

extending and fixing at least one length of a functional element coextensively with the first piece of fabric, wherein said functional element is selected from the group consisting of;

insulated single and multi-stranded metallic wires, noninsulated single and multi-stranded metallic wires, metallic coated polymeric fibers, inherently conductive polymer fibers, optical fibers, plastic optical fibers, silica glass optical fibers, electrically conductive composite yarns, and metallic coated films;

securing the extended length of the functional element to the first surface of said first piece of fabric along a substantial portion of the fixed length thereof;

providing a length of a piece of having a first surface and second surface; and

securing said piece of either to the functional element or to the first surface of said first piece of fabric along a substantial portion of the length thereof coextending with said functional element to form the functional laminate,

wherein the width of said at least one via opening is at least as large or is larger than a diameter or width of the functional element, wherein the functional element does not penetrate into or through either of the first piece of fabric or the piece of inextensible material, and wherein at least a portion of the functional element is exposed to an environment external to the functional laminate through the at least one via.

2. The method of claim 1, wherein at least two lengths of functional elements are extended and fixed to be substantially parallel or coextensive.

3. The method of claim 1, wherein the fabric is selected from the group consisting of nonwoven fabric, woven fabric and knit fabric.

4. The method of claim 1, wherein the at least one via opening is selected from the group consisting of a hole, a slit or a slot.

5. The method of claim 4, further comprising perforating the piece of inextensible material to form at least one other via opening.

6. The method of claim 1, further comprising the steps of:

(i) folding a distal end of the functional laminate back onto itself at least one time; and

(ii) fastening such folded end to an outer surface of one outer layer.

7. The method of claim 6, wherein fastening is by a mechanical fastening mechanism selected from the group consisting of gluing, riveting, snapping, stitching, stapling, welding, and encasing.

8. The method of claim 1, further comprising the step of attaching at least one connector to the functional laminate, wherein said connector is adaptable for connecting the at least one functional element in the laminate to a source selected from the group consisting of electricity and radiation.

9. The method of claim 8, further comprising connecting a source of electricity to the at least one functional element.

10. The method of claim 8, further comprising connecting a source of radiation to the at least one functional element.

11. The method of claim 1, wherein the inextensible material is a fabric or film selected from the group consisting of:

nonwoven fabric, woven fabric, knit fabric, paper and polymer film.

12. The method of claim 1, wherein the inextensible material is a fabric.