Woven electronic textile, yarn and article

• US 20040009729A1
• Filed: 02/13/2003
• Published: 01/15/2004
• Est. Priority Date: 05/10/2002
• Status: Active Grant

• Current Assignee: Sarnoff Corporation (SRI International, Inc.)
• Original Assignee: Sarnoff Corporation (SRI International, Inc.)
• Inventors: Palanisamy, Ponnusamy, Riddle, George Herbert Needham, Hill, Ian Gregory, Trotz, Seth, Carpinelli, Joseph M., Matthies, Dennis L.
• Granted Patent: US 7,592,276 B2
• Time in Patent Office: Days
• US Class Current: 442/208
• CPC Class Codes: A41D 1/005 with embedded cable or connector
• CPC Class Codes: A41D 13/1281 with incorporated means for medical monitoring
• CPC Class Codes: A41D 31/04 characterised by special function or use protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes A62B17/00; composition of materials for coverings or clothing affording protection against harmful chemical agents A62D5/00
• CPC Class Codes: D02G 3/441 Yarns or threads with antistatic, conductive or radiation-shielding properties electroconductive, anti-static or radiation-shielding filaments D01F1/09, D01F1/106; anti-static fabrics D03D15/533; conducting, insulating or anti-static layers for floor coverings D06N7/0042
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 11/00 Double or multi-ply fabrics not otherwise provided for
• 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 15/258 Noble metal
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/46 Flat yarns, e.g. tapes or films
• CPC Class Codes: D10B 2101/20 Metallic fibres
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2201/04 Linen
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2211/04 Silk
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: D10B 2501/00 Wearing apparel
• CPC Class Codes: D10B 2501/04 Outerwear; Protective garments
• CPC Class Codes: D10B 2503/06 Bed linen
• CPC Class Codes: D10B 2503/10 : Umbrellas
• CPC Class Codes: D10B 2505/18 : Outdoor fabrics, e.g. tents, tarpaulins D10B2507/00 takes precedence
• CPC Class Codes: D10B 2507/06 : Parachutes
• CPC Class Codes: G06F 3/14 : Digital output to display device ; Cooperation and interconnection of the display device with other functional units
• CPC Class Codes: G06F 3/147 : using display panels
• CPC Class Codes: G09G 2380/02 : Flexible displays
• CPC Class Codes: H01R 4/02 : Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/04 : using electrically conductive adhesives
• 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: Y10S 428/913 : Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10S 428/917 : Electroluminescent
• 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 442/3195 : Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/322 : Warp differs from weft
• CPC Class Codes: Y10T 442/339 : Metal or metal-coated strand
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

A woven article comprises a plurality of electrically insulating and/or electrically conductive yarn in the warp and a plurality of electrically insulating and/or electrically conductive yarn in the weft interwoven with the yarn in the warp. A functional yarn in the warp and/or the weft comprises an elongate substrate including at least one electrical conductor and at least one electronic device thereon, wherein the at least one electrical conductor provides directly and/or indirectly an electrical contact for connecting to the electronic device.

Claims

1. A woven article having an electronic function woven therein comprising:

warp yarn and weft yarn interwoven;

at least one electrically conductive yarn disposed in one of the warp or the weft; and

at least one functional yarn disposed in the other of the warp and the weft, said functional yarn comprising;

an elongate substrate including at least one electrical conductor disposed thereon, and

at least one electronic device on said elongate substrate,

wherein the at least one electrical conductor electrically connects said electronic device and said at least one electrically conductive yarn.

2. The woven article of claim 1 wherein said at least one electrically conductive yarn and said at least one electrical conductor of said functional yarn electrically connect at one or more of:

an exposed portion of said at least one electrical conductor;

an exposed portion of said at least one electrical conductor proximate an end of said elongate substrate;

a contact in electrical connection with said at least one electrical conductor; and

/or

a contact proximate an end of said elongate substrate and electrically connected with said at least one electrical conductor.

3. The woven article of claim 1 wherein said at least one electrically conductive yarn and said at least one electrical conductor of said functional yarn are in electrical contact at a location where said at least one electrically conductive yarn crosses said functional yarn in the woven article without a mechanical attaching thereof at that location.

4. The woven article of claim 1:

wherein said at least one electrical conductor includes a signal and/or data conductor; and

wherein said at least one electronic device is addressable via the signal and/or data conductor for controlling and/or activating at least a second electronic device; and

/or

wherein said at least one electronic device is addressable by passive matrix addressing, active matrix addressing, serial addressing, parallel addressing, scanned addressing, active addressing, block addressing, and/or individual addressing.

5. The woven article of claim 1 wherein said at least one electronic device, includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

6. The woven article of claim 1 embodied in a fabric, a textile, a consumer article, a professional article, a commercial article, a government article, a military article, programmable alpha-numeric signage, a traffic warning sign, an advertising sign, a window sign, a banner, a portable sign, a garment, an article of clothing, an article and/or garment for a baby and/or an infant, a safety-wear bib, a vest, a safety garment, a personal flotation device, life saving apparatus, footwear, a blanket, a medical device, a light blanket, a warming blanket, a sensing blanket, apparatus and/or equipment for sport, sports wear, a uniform, a toy, an entertainment device, truck signage, vehicle signage, a construction and/or work area sign, a directional sign, lighting, emergency lighting, a lighting panel, a decorative light, an accent light, a reading light, lighting for a tent, tarp, canvas and/or umbrella, display lighting, a sensor fabric, an environmental and/or chemical and/or biological agent sensor array, camouflage, a parachute a light sensing array, and/or an imaging array.

7. A woven article having a warp and a weft comprising:

a plurality of electrically insulating and/or electrically conductive yarn in the warp;

a plurality of electrically insulating and/or electrically conductive yarn in the weft interwoven with said plurality of electrically insulating and/or electrically conductive yarn in the warp; and

at least one functional yarn disposed in one of the warp and the weft adjacent an electrically insulating yarn thereof, said functional yarn comprising;

an elongate substrate including at least one electrical conductor disposed thereon,

at least one electronic device on said elongate substrate,

wherein the at least one electrical conductor provides directly and/or indirectly an electrical contact for connecting to said electronic device.

8. The woven article of claim 7 wherein said at least one functional yarn is interwoven to cross at least one electrically conductive yarn and to connect thereto at the crossing, wherein the at least one electrical conductor provides indirectly via said at least one electrically conductive yarn an electrical contact for connecting to said electronic device.

9. The woven article of claim 7 wherein said at least one electrical conductor of said functional yarn is in electrical contact with an electrically conductive yarn at a location where said functional yarn crosses said electrically conductive yarn in the woven article without a mechanical attaching of said functional yarn and said electrically conductive yarn at said location.

10. The woven article of claim 7 wherein at least one electrically conductive yarn in the warp or the weft and said at least one electrical conductor of said functional yarn electrically connect at one or more of:

an exposed portion of said at least one electrical conductor;

an exposed portion of said at least one electrical conductor proximate an end of said elongate substrate;

a contact in electrical connection with said at least one electrical conductor; and

/or

a contact proximate an end of said elongate substrate and electrically connected with said at least one electrical conductor.

11. The woven article of claim 7:

wherein said at least one electrical conductor includes a signal and/or data conductor, and wherein said at least one electronic device is addressable via the signal and/or data conductor for controlling and/or activating at least a second electronic device; and

/or

wherein said at least one electronic device is addressable by passive matrix addressing, active matrix addressing, serial addressing, parallel addressing, scanned addressing, active addressing, block addressing, and/or individual addressing.

12. The woven article of claim 7 wherein said at least one electronic device includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

13. The woven article of claim 7 embodied in a fabric, a textile, a consumer article, a professional article, a commercial article, a government article, a military article, programmable alpha-numeric signage, a traffic warning sign, an advertising sign, a window sign, a banner, a portable sign, a garment, an article of clothing, an article and/or garment for a baby and/or an infant, a safety-wear bib, a vest, a safety garment, a personal flotation device, life saving apparatus, footwear, a blanket, a medical device, a light blanket, a warming blanket, a sensing blanket, apparatus and/or equipment for sport, sports wear, a uniform, a toy, an entertainment device, truck signage, vehicle signage, a construction and/or work area sign, a directional sign, lighting, emergency lighting, a lighting panel, a decorative light, an accent light, a reading light, lighting for a tent, tarp, canvas and/or umbrella, display lighting, a sensor fabric, an environmental and/or chemical and/or biological agent sensor array, camouflage, a parachute a light sensing array, and/or an imaging array.

14. A yarn for weaving in a fabric and/or textile and providing an electrical function comprising:

an elongate substrate including at least one electrical conductor disposed thereon,

a plurality of electronic devices disposed on said elongate substrate, each having at least one connection to the at least one electrical conductor; and

means for electrically connecting to said at least one electrical conductor.

15. The yarn of claim 14 wherein said elongate substrate comprises a long, thin strip of electrically insulating material having two opposing surfaces, wherein the at least one electrical conductor and said plurality of electronic devices are disposed on one of the opposing surfaces.

16. The yarn of claim 14 wherein said means for electrically connecting to said at least one electrical conductor includes one or more of:

an exposed portion of said at least one electrical conductor;

an exposed portion of said at least one electrical conductor proximate an end of said elongate substrate;

a contact in electrical connection with said at least one electrical conductor; and

/or

a contact proximate an end of said elongate substrate and electrically connected with said at least one electrical conductor.

17. The yarn of claim 14 wherein said at least one electrical conductor comprises:

first and second electrical conductors disposed side by side along substantially the length of said elongate substrate;

power and ground electrical conductors disposed side by side along substantially the length of said elongate substrate;

power and ground and signal conductors disposed side by side along substantially the length of said elongate substrate;

power and ground and data conductors disposed side by side along substantially the length of said elongate substrate; and

/or

a plurality of electrical conductors disposed along said elongate substrate for connecting said plurality of electronic devices in series connection.

18. The yarn of claim 17 wherein said plurality of electronic devices are connected in parallel between said first and second electrical conductors and/or between said power and ground conductors.

19. The yarn of claim 17 wherein said data conductor and/or said signal conductor provide addressing signals to one or more of said plurality of electronic devices and/or carry signals generated by one or more of said plurality of electronic devices.

20. The yarn of claim 17 wherein one or more of said plurality of electronic devices is addressable via the signal and/or data conductors for controlling and/or activating others of said plurality of electronic devices.

21. The yarn of claim 14 further comprising:

one or more registration indicia on a surface of said elongate substrate in predetermined position with respect to at least one of said plurality of electronic devices and/or said at least one electrical conductor; and

/or

a coating over the plurality of electronic devices disposed on said elongate substrate.

22. The yarn of claim 14 wherein said plurality of electronic devices includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

23. A functional yarn for weaving comprising:

an elongate strip of electrically insulating yarn substrate having a first elongate surface;

first and second electrical conductors disposed along the first elongate surface of said elongate strip of electrically insulating yarn substrate and defining at least one contact;

a plurality of electronic devices disposed on said elongate strip of electrically insulating yarn substrate, each of said electronic devices having at least first and second terminals connected to the first and second electrical conductors, respectively; and

one or more registration indicia on the first elongate surface of said elongate strip of electrically insulating yarn substrate in predetermined position with respect to at least one of said plurality of electronic devices and/or the contact defined by said first and second electrical conductors.

24. The functional yarn of claim 23 in combination with an electrically conductive yarn crossing said functional yarn making electrical connection with one of said first and second electrical conductors, wherein said functional yarn and said electrically conductive yarn are interwoven with insulating yarn to provide a fabric and/or textile.

25. The functional yarn of claim 23 wherein said plurality of electronic devices includes one or more of a temperature sensor, a chemical sensor, a biological sensor, a sensor of force, pressure, sound, an electric field, a magnetic field, light, acceleration and/or an environmental condition, a source of light, force, heat, electromagnetic radiation and/or sound, an infra red and/or wireless transmitter and/or receiver, an imager, a CCD imager, a thermoelectric sensor, cooler, heater and/or generator, a liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a microphone, a loudspeaker, an acoustic transducer, a resistor, a processor, a digital signal processor, a microprocessor, a micro-controller, a CPU, an analog-to-digital converter, a digital-to-analog converter, a data-producing device, a data-utilizing device, a processing device, a switch, a human-interface device, a human-input device, a blinker and/or flasher, a battery, a solar cell, a photovoltaic device, a power source, and/or an addressable device.

26. A method for weaving a fabric and/or a textile article having a warp and a weft comprising:

providing a plurality of electrically insulating yarn and/or electrically conductive yarn in the warp;

weaving a plurality of electrically insulating yarn and/or electrically conductive yarn in the weft with said plurality of electrically insulating yarn and/or electrically conductive yarn in the warp; and

weaving at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn thereof, wherein the functional yarn comprises an elongate substrate including at least one electrical conductor disposed thereon and at least one electronic device on the elongate substrate and electrically connected to the at least one electrical conductor thereon,

wherein the at least one electrical conductor and at least one electrically conductive yarn in the other of the warp and the weft cross for providing an electrical connection to the electronic device.

27. The method of claim 26 wherein the at least one functional yarn is in the weft and includes at least one registration indicia, further comprising:

sensing the at least one registration indicia of the at least one functional yarn during said weaving at least one functional yarn; and

registering the at least one functional yarn in the weft in response to the sensed at least one registration indicia.

28. The method of claim 26 wherein said weaving a plurality of electrically insulating yarn and/or electrically conductive yarn and said weaving at least one functional yarn include controlling a tightness of the weave and/or a density of yarn for maintaining the at least one electrical conductor of the functional yarn in electrical contact with an electrically conductive yarn at a location where the functional yarn crosses the electrically conductive yarn in the woven fabric and/or article without mechanically attaching the functional yarn and the electrically conductive yarn at that location.

29. A woven article having an electronic function woven therein comprising:

warp yarn and weft yarn interwoven;

at least one electrically conductive yarn disposed in one of the warp or the weft, wherein said electrically conductive yarn includes a conductor on a surface thereof; and

at least one electrically conductive yarn disposed in the other of the warp or the weft, wherein said electrically conductive yarn includes a conductor on a surface thereof and an optically-active layer on the conductor thereof;

wherein the conductor of the at least one of the at least one electrically conductive yarn disposed in the warp and/or the conductor of the at least one electrically conductive yarn disposed in the weft is optically transparent, and,

wherein the at least one electrically conductive yarn in the weft and the at least one electrically conductive yarn in the warp define at a crossing thereof an optically-active element comprising first and second electrodes defined by the respective conductors of the at least one electrically conductive yarn disposed in the warp and of the at least one electrically conductive yarn disposed in the weft, wherein the optically-active layer thereat is disposed between the first and second electrodes; and

at least one functional yarn disposed in the warp and/or in the weft, said functional yarn comprising;

an elongate substrate including a pattern of electrical conductors disposed thereon and defining contacts, and

at least one electronic device on said elongate substrate and connected to the pattern of electrical conductors for providing electrical signals at the contacts thereof,

wherein the contacts of the pattern of electrical conductors of said functional yarn electrically connects said electronic device thereof and said at least one electrically conductive yarn in the weft and/or in the warp.

30. The woven article of claim 29 wherein the at least one of the at least one electrically conductive yarn disposed in the warp or the at least one electrically conductive yarn disposed in the weft is colored for providing optically active elements that appear colored.

31. The woven article of claim 29 wherein the at least one electronic device of said functional yarn provides electrical drive signals to the optically-active element defined at a crossing of said at least one electrically conductive yarn in the weft and said at least one electrically conductive yarn in the warp.

32. The woven article of claim 29 comprising a plurality of said electrically conductive yarn in the weft and a plurality of said electrically conductive yarn in the warp, and at least one functional yarn in each of the warp and the weft, wherein N of said electrically conductive yarn in the weft and M of said electrically conductive yarn in the warp are driven as a block by one of said at least one functional yarn in the warp and one of said at least one functional yarn in the weft, wherein N and M are positive integers.

33. The woven article of claim 29 further comprising solder or electrically conductive adhesive connections of the respective contacts of the patterns of electrical conductors of said functional yarn to the respective conductors of the electrically conductive weft and/or warp yarn.

34. The woven article of claim 29 wherein the optically-active layer of the at least one electrically conductive yarn disposed in the other of the warp or the weft comprises one or more of a sensor of light or electromagnetic radiation, a source of light or electromagnetic radiation, an imager, a CCD imager, a liquid crystal element, a polymer dispersed liquid crystal element, an electro-luminescent element, an organic light-emitting element, an OLED, an electrophoretic element, an LED, a piezo-electric element and/or transducer, a data-producing device, a data-utilizing device, a blinker and/or a flasher, and/or a photovoltaic device.