Methods of interconnecting components on fabrics using metal braids

• US 9,839,125 B1
• Filed: 04/30/2014
• Issued: 12/05/2017
• Est. Priority Date: 12/09/2013
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Liu, Weifeng, Feng, Zhen, Mohammed, Anwar
• Primary Examiner(s): Thomas, Eric
• Assistant Examiner(s): McFadden, Michael P
• Application Number:
  US14/266,723
• Time in Patent Office: 1,315 Days
• Field of Search: 361767
• 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 1/005 with embedded cable or connector
• CPC Class Codes: D05B 17/00 Sewing machines for concurrently making thread and welded seams for making non-welded fluid-tight seams D05B1/26
• CPC Class Codes: H01M 10/0436 Small-sized flat cells or batteries for portable equipment
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: H01R 4/00 Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
• CPC Class Codes: H01R 4/02 Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/029 Welded connections H01R4/021 - H01R4/028 take precedence
• CPC Class Codes: H01R 43/005 for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
• CPC Class Codes: H01R 43/02 for soldered or welded connections
• CPC Class Codes: H01R 43/0235 for applying solder H01R43/0228 takes precedence
• CPC Class Codes: H05K 1/0271 Arrangements for reducing stress or warp in rigid printed circuit boards, e.g. caused by loads, vibrations or differences in thermal expansion
• CPC Class Codes: H05K 1/0296 Conductive pattern lay-out details not covered by sub groups H05K1/02 - H05K1/0295 H05K1/11 takes precedence; lay-out adapted to mounted component configuration H05K1/18
• CPC Class Codes: H05K 1/0298 Multilayer circuits
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 1/0366 reinforced, e.g. by fibres, fabrics H05K1/036 takes precedence
• CPC Class Codes: H05K 1/0373 containing additives, e.g. fillers H05K1/036 takes precedence
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 1/09 : Use of materials for the conductive, e.g. metallic pattern
• CPC Class Codes: H05K 1/11 : Printed elements for providing electric connections to or between printed circuits
• CPC Class Codes: H05K 1/111 : Pads for surface mounting, e.g. lay-out
• CPC Class Codes: H05K 1/112 : directly combined with via connections
• CPC Class Codes: H05K 1/115 : Via connections; Lands around holes or via connections H05K1/112 takes precedence
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 1/181 : associated with surface mounted components
• CPC Class Codes: H05K 1/189 : characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 13/04 : Mounting of components , e.g. of leadless components
• CPC Class Codes: H05K 2201/0154 : Polyimide
• CPC Class Codes: H05K 2201/0158 : Polyalkene or polyolefin, e.g. polyethylene [PE], polypropylene [PP]
• CPC Class Codes: H05K 2201/0162 : Silicon containing polymer, e.g. silicone
• CPC Class Codes: H05K 2201/0287 : Unidirectional or parallel fibers
• CPC Class Codes: H05K 2201/05 : Flexible printed circuits [FPCs]
• CPC Class Codes: H05K 2201/09418 : Special orientation of pads, lands or terminals of component, e.g. radial or polygonal orientation
• CPC Class Codes: H05K 3/284 : for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/30 : Assembling printed circuits with electric components, e.g. with resistor
• CPC Class Codes: H05K 3/305 : Affixing by adhesive
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: H05K 3/4015 : using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres
• CPC Class Codes: H05K 3/42 : Plated through-holes or plated via connections
• CPC Class Codes: H05K 3/4644 : by building the multilayer layer by layer, i.e. build-up multilayer circuits making via holes in the insulating layers H05K3/0011; special circuit boards as base or core whereon the multilayer is built H05K3/4602
• CPC Class Codes: H05K 7/02 : Arrangements of circuit components or wiring on supporting structure
• 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: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

An electronics assembly includes multiple electronic components coupled to a fabric. Each of the multiple electronic components includes one or more electrical connection points, such as a bond pad or solder bump. The electronics assembly also includes one or more electrically conductive wire braids, one electrically conductive wire braid coupled to one electrical connection point on an electronic component. One of the electrically conductive wire braids interconnects two electronic components, thereby providing an electrical connection between the two electronic components. The electrically conductive wire braid can be attached to the fabric by an adhesive, a stitched thread, which can be either electrically insulated or electrically conductive, or both adhesive and stitched thread. The fabric can be a wearable fabric, such as a shirt or pants, or other form to be worn by a user, such as an armband, waistband, hat or shoes.

Claims

1. An electronics assembly comprising:

a. a fabric;

b. a first electronic component comprising a first electrical connection point;

c. a second electronic component comprising a second electrical connection point; and

c. an electrically conductive wire braid coupled to the fabric, wherein the electrically conductive wire braid comprises a first portion coupled to the first electrical connection point of the first electronic component and a second portion coupled to the second electrical connection point of the second electronic component such that an electrical connection is formed between the first electrical connection point and the second electrical connection point via the electrically conductive wire braid, wherein the electrically conductive wire braid is a single continuous braid from a first end to a second end, the first portion includes the first end and the second portion includes the second end.

2. The electronics assembly of claim 1 wherein the first electrical connection point and the second electrical connection point each comprise a bond pad.

3. The electronics assembly of claim 1 wherein the first electrical connection point and the second electrical connection point each comprise a solder bump.

4. The electronics assembly of claim 1 wherein the first electrical connection point is coupled to the first portion of the electrically conductive wire braid and the second electrical connection point is coupled to the second portion of the electrically conductive wire braid via a solder joint, a welded joint or an electrically conductive adhesive.

5. The electronics assembly of claim 1 wherein the electrically conductive wire braid is coupled to the fabric using an adhesive.

6. The electronics assembly of claim 1 wherein the electrically conductive wire braid is coupled to the fabric using a non-electrically conductive thread stitched to the fabric and to the electrically conductive wire braid.

7. The electronics assembly of claim 1 wherein the electrically conductive wire braid is coupled to the fabric using an electrically conductive thread stitched through the fabric and through the electrically conductive wire braid.

8. The electronics assembly of claim 1 wherein the electrically conductive wire braid comprises a plurality of electrically conductive wires, and each of the plurality of electrically conductive wires comprise a metal wire made of one or more of copper, silver, nickel and their alloys.

9. The electronics assembly of claim 1 wherein the electrically conductive wire braid comprises a plurality of electrically conductive wires, and each of the plurality of electrically conductive wires comprise an electrically conductive plating finish.

10. The electronics assembly of claim 1 wherein the electrically conductive wire braid comprises a plurality of electrically conductive wires braided together.

11. The electronics assembly of claim 1 further comprising an encapsulation layer coupled to the first electronic component, the second electronic component and the electrically conductive wire braid.

12. The electronics assembly of claim 1 wherein the first electronic component comprises a third electrical connection point, and the electronics assembly further comprises a second electrically conductive wire braid coupled to the third electrical connection point.

13. The electronics assembly of claim 12 further comprising an electrically conductive wire stitched to the fabric and to the second electrically conductive wire braid such that an electrical connection is formed between the electrically conductive wire and the second electrically conductive wire braid.

14. The electronics assembly of claim 13 wherein the second electrically conductive wire braid is coupled to the fabric using an adhesive.

15. The electronics assembly of claim 13 wherein the second electrically conductive wire braid is coupled to the fabric using a non-electrically conductive thread stitched to the fabric and to the second electrically conductive wire braid.

16. The electronics assembly of claim 13 wherein the second electrically conductive wire braid is coupled to the fabric using a second electrically conductive thread stitched to the fabric and to the second electrically conductive wire braid.

17. The electronics assembly of claim 13 wherein the fabric comprises an insulated wire including an inner metal wire and an outer insulation layer, further wherein the electrically conductive wire is electrically coupled to the inner metal wire of the insulated wire.

18. The electronics assembly of claim 13 wherein the electrically conductive wire stitched to the fabric comprises two separate wires, wherein the two separate wires comprise a metal wire and an insulation wire.

19. The electronics assembly of claim 1 wherein the electronics assembly is wearable.

31. The method of claim 15 wherein the fabric comprises an insulated wire including an inner metal wire and an outer insulation layer, and the method further comprises electrically coupling the electrically conductive wire to the inner metal wire of the insulated wire.

32. The method of claim 15 wherein the electrically conductive wire stitched to the fabric comprises two separate wires, wherein the two separate wires comprise a metal wire and an insulation wire, and stitching the electrically conductive wire to the fabric comprises stitching the two separate wires.

33. The method of claim 15 wherein the electronics assembly is wearable.

34. The electronics assembly of claim 1 wherein the first portion of the electrically conductive wire braid is stacked between the fabric and the first electrical connection point of the first electronic component, and the second portion of the electrically conductive wire braid is stacked between the fabric and the second electrical connection point of the second electronic component.

36. The electronics assembly of claim 1 wherein the electrically conductive wire braid exclusively interconnects two electrical connection points, the two electrical connection points are the first electrical connection point of the first electronic component at the first portion of the electrically conductive wire braid and the second electrical connection point of the second electronic component at the second portion of the electrically conductive wire braid.

20. A method of making an electronics assembly, the method comprising:

a. attaching a first electrical connection point of a first electronic component to a first portion of an electrically conductive wire braid, thereby forming an electrical connection between the electrically conductive wire braid and the first electrical connection point;

b. attaching a second electrical connection point of a second electronic component to a second portion of the electrically conductive wire braid, thereby forming an electrical connection between the electrically conductive wire braid and the second electrical connection point such that an electrical connection is formed between the first electrical connection point and the second electrical connection point via the electrically conductive wire braid, wherein the electrically conductive wire braid is a single continuous braid from a first end to a second end, the first portion includes the first end and the second portion includes the second end; and

c. attaching the electrically conductive wire braid to a fabric.

21. The method of claim 20 wherein attaching the first electrical connection point of the first electronic component to the first portion of the electrically conductive wire braid and attaching the second electrical connection point of the second electronic component to the second portion of the electrically conductive wire braid comprises soldering, welding or using an electrically conductive adhesive.

22. The method of claim 20 wherein attaching the electrically conductive wire braid to the fabric comprises using an adhesive.

23. The method of claim 20 wherein attaching the electrically conductive wire braid to the fabric comprises stitching a non-electrically conductive thread to the electrically conductive wire braid and to the fabric.

24. The method of claim 20 wherein attaching the electrically conductive wire braid to the fabric comprises stitching an electrically conductive thread through the electrically conductive wire braid and through the fabric.

25. The method of claim 20 further comprising adding an encapsulation layer coupled to the first electronic component, the second electronic component and the electrically conductive wire braid.

26. The method of claim 20 wherein the first electronic component comprises a third electrical connection point, and the electronics assembly further comprises a second electrically conductive wire braid, wherein the method further comprises attaching a first portion of the second electrically conductive wire braid to the third electrical connection point.

27. The method of claim 26 further comprising stitching an electrically conductive wire to the fabric and to a second portion of the second electrically conductive wire braid such that an electrical connection is formed between the electrically conductive wire and the second electrically conductive wire braid.

28. The method of claim 27 further comprising attaching the second electrically conductive wire braid to the fabric using an adhesive.

29. The method of claim 27 further comprising attaching the second electrically conductive wire braid to the fabric using a non-electrically conductive thread stitched to the fabric and to the second electrically conductive wire braid.

30. The method of claim 27 further comprising attaching the second electrically conductive wire braid to the fabric using a second electrically conductive thread stitched to the fabric and to the second electrically conductive wire braid.

35. The electronics assembly of claim 20 wherein the first portion of the electrically conductive wire braid is stacked between the fabric and the first electrical connection point of the first electronic component, and the second portion of the electrically conductive wire braid is stacked between the fabric and the second electrical connection point of the second electronic component.