SMART TEXTILE PRODUCT AND METHOD FOR FABRICATING THE SAME

• US 20170231089A1
• Filed: 09/17/2015
• Published: 08/10/2017
• Est. Priority Date: 09/29/2014
• Status: Active Grant

• Current Assignee: IMEC International, Universiteit Gent Vzw
• Original Assignee: IMEC International, Universiteit Gent Vzw
• Inventors: Van Keymeulen, Bjorn
• Granted Patent: US 9,839,123 B2
• Time in Patent Office: Days
• CPC Class Codes: H05K 1/0283 Stretchable printed circuits
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 1/111 Pads for surface mounting, e.g. lay-out
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/0133 Elastomeric or compliant polymer elastomeric conductor H05K2201/0314
• CPC Class Codes: H05K 2201/0281 Conductive fibers
• CPC Class Codes: H05K 2201/10977 Encapsulated connections applying non-metallic protective coatings for encapsulating mounted components H05K3/284
• CPC Class Codes: H05K 2203/1316 Moulded encapsulation of mounted components
• CPC Class Codes: H05K 2203/1322 Encapsulation comprising more than one layer
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/32 electrically connecting electric components or wires to printed circuits

Abstract

The present disclosure relates to a smart textile product and a method for manufacturing a smart textile product. The smart textile product is provided with a flexible and/or stretchable textile fabric (10) comprising a plurality of electrically conductive threads (11, 12) and at least one rigid electronic or optoelectronic component (20) comprising at least one electrically conductive pad (21, 22), which is in electrical contact with at least one of the plurality of electrically conductive threads. The smart textile product (10) comprises an elastomeric encapsulation layer (31) in which the electrical connection (1, 2) is embedded, so as to provide a gradual transition in deformability between the flexible and/or stretchable textile fabric (10) and the at least one rigid component (20) at the location of the at least one electrical connection (1, 2).

Claims

1-25. -25. (canceled)

26. A smart textile product comprising:

a flexible and/or stretchable textile fabric comprising a plurality of electrically conductive threads;

at least one rigid electronic or optoelectronic component comprising at least one electrically conductive pad, the at least one electrically conductive pad being configured to be in electrical contact with at least one of the plurality of electrically conductive threads to provide at least one electrical connection between the at least one rigid electronic or optoelectronic component and the at least one of the electrically conductive threads of the flexible and/or stretchable textile fabric; and

at least one elastomeric encapsulation layer, wherein the at least one electrical connection is embedded in the at least one elastomeric encapsulation layer to provide a gradual transition in deformability between the flexible and/or stretchable textile fabric and the at least one rigid component at a location of the at least one electrical connection.

27. The smart textile product according to claim 26, wherein the at least one rigid electronic or optoelectronic component is at least partly embedded in the at least one encapsulation layer.

28. The smart textile product according to claim 26, wherein the at least one electrically conductive pad is configured to be connected to the at least one electrically conductive thread by an electrically conductive material.

29. The smart textile product according to claim 28, wherein the electrically conductive material is an adhesive material.

30. The smart textile product according to claim 28, wherein the electrically conductive material is a solder material.

31. The smart textile product according to claim 26, wherein the plurality of electrically conductive threads are separated by a gap.

32. The smart textile product according to claim 26, wherein the plurality of electrically conductive threads are substantially parallel to one another.

33. The smart textile product according to claim 26, wherein the elastomeric encapsulation layer is a silicon based material or a polydimethylsiloxane.

34. The smart textile product according to claim 26, wherein the at least one elastomeric encapsulation layer comprises a first elastomeric encapsulation layer comprising a first elastomer and a second elastomeric encapsulation layer comprising a second elastomer different from the first elastomer.

35. The smart textile product according to claim 34, wherein the first elastomer is selected for optimizing a reduction of mechanical stress at the location of the at least one electrical connection and wherein the second elastomer is selected to provide protection against chemical substances, humidity or moisture.

36. The smart textile product according to claim 34, wherein the first elastomer and the second elastomer are selected to provide a gradually increasing deformability between the rigid component and the fabric.

37. A method for fabricating a smart textile product according to claim 26, comprising:

providing a flexible and/or stretchable textile fabric comprising a plurality of electrically conductive threads;

providing a rigid electronic or optoelectronic component comprising at least one electrically conductive pad;

forming at least one electrical connection between the rigid electronic or optoelectronic component and at least one of the plurality of electrical conductive threads; and

forming at least one elastomeric encapsulation layer at a location of the at least one electrical connection, wherein the at least one electrical connection is embedded in the at least one encapsulation layer to provide a gradual transition in deformability between the flexible and/or stretchable textile fabric and the at least one rigid electronic or optoelectronic component at the location of the at least one electrical connection.

38. The method according to claim 37, wherein the forming the at least one elastomeric encapsulation layer comprises:

providing a liquid precursor of an elastomeric material on the flexible and/or stretchable textile fabric;

waiting for a predetermined period of time to allow the liquid precursor to penetrate into the flexible and/or stretchable textile fabric and to surround the at least one electrical connection; and

curing the liquid precursor, thereby forming an elastomeric encapsulation layer.

39. The method according to claim 38, wherein the liquid precursor is provided adjacent to at least one lateral edge of the rigid electronic or optoelectronic component.

40. The method according to claim 38, wherein the providing the liquid precursor comprises covering at least partially the rigid electronic or optoelectronic component.

41. The method according to claim 38, wherein the providing the liquid precursor comprises dispensing the liquid precursor.

42. The method according to claim 38, wherein the providing the liquid precursor comprises:

positioning a mold on the flexible and/or stretchable textile fabric; and

filling the mold with the liquid precursor.

43. The method according to claim 42, wherein the mold is positioned on the flexible and/or stretchable textile fabric such that it covers the electronic or optoelectronic component and the at least one electrical connection.

44. The method according to claim 38, wherein the predetermined period of time is selected based on a viscosity of the liquid precursor and an absorption rate of the flexible and/or stretchable textile fabric.

45. The method according to claim 38, wherein the forming at least one elastomeric encapsulation layer comprises forming a first elastomeric encapsulation layer comprising a first elastomer and forming a second elastomeric encapsulation layer comprising a second elastomer, wherein the first layer and the second layer are formed by:

providing a first liquid precursor of a first elastomeric material on the flexible and/or stretchable textile fabric;

waiting for a predetermined period of time to allow the first liquid precursor to penetrate into the flexible and/or stretchable textile fabric and to surround the at least one electrical connection;

curing the liquid precursor, thereby forming the first elastomeric encapsulation layer;

providing a second liquid precursor of a second elastomeric material on the flexible and/or stretchable textile fabric;

waiting for a predetermined period of time to allow the second liquid precursor to penetrate into the flexible and/or stretchable textile fabric and to surround the first elastomeric encapsulation layer; and

curing the second liquid precursor, thereby forming the second elastomeric encapsulation layer.