Method and apparatus to create electrical junctions for information routing in textile structures

• US 7,299,964 B2
• Filed: 01/15/2004
• Issued: 11/27/2007
• Est. Priority Date: 01/15/2004
• Status: Expired due to Fees

• Current Assignee: Georgia Institute of Technology (University System of Georgia)
• Original Assignee: Georgia Tech Research Corporation (University System of Georgia)
• Inventors: Park, Sungmee, Jayaraman, Sundaresan
• Primary Examiner(s): Johnson; Jonathan
• Assistant Examiner(s): Beveridge; Rachel E.
• Application Number:
  US10/759,691
• Publication Number:
  US 20050156015A1
• Time in Patent Office: 1,412 Days
• Field of Search: 228/110.1, 228/121, 228/248.1, 298/46, 139/273.R, 139/353, 139/383.R, 139/387.R, 226/4, 290/5, 442/209
• US Class Current: 228/110.1
• CPC Class Codes: H01H 2203/0085 Layered switches integrated into garment, clothes or textile
• CPC Class Codes: H01R 43/0207 Ultrasonic-, H.F.-, cold- or impact welding
• CPC Class Codes: H05K 1/0289 having a matrix lay-out, i.e. having selectively interconnectable sets of X-conductors and Y-conductors in different planes
• 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 2203/0126 Dispenser, e.g. for solder paste, for supplying conductive paste for screen printing or for filling holes
• CPC Class Codes: H05K 2203/0783 Using solvent, e.g. for cleaning; Regulating solvent content of pastes or coatings for adjusting the viscosity
• 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: H05K 3/328 by welding
• CPC Class Codes: H05K 3/4069 for via connections in organic insulating substrates
• CPC Class Codes: H05K 3/4084 by deforming at least one of the conductive layers
• CPC Class Codes: Y10S 2/905 Electric
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 442/3228 Materials differ

Abstract

Disclosed are systems or apparatuses and methods for forming a junction between conductive fibers that are incorporated into a fabric. Briefly, one method includes the steps of removing insulation from two intersecting individually insulated conductive fibers to expose the individually conductive fibers, bringing the exposed individually conductive fibers into contact with each other at a junction point, and forming a molecular bond between the conductive fibers at the junction point. Also disclosed are systems for forming a junction between conductive fibers that are incorporated into a fabric. In this regard, one embodiment of such a system can include a first apparatus that removes insulation from two intersecting individually insulated conductive fibers to expose the individually conductive fibers, a second apparatus that brings the exposed individually conductive fibers into contact with each other at a junction point, and a third apparatus that aids in formation of a molecular bond between the conductive fibers at the junction point.

Claims

1. A method of forming a junction or switch between at least two conductors incorporated into a fabric, comprising the steps of:

providing a fabric with at least two overlapping conductors or sections of a conductor incorporated therein wherein the conductors or sections are individually insulated conductive fibers;

removing insulation at the junction point from the conductors or sections to expose conductive fiber, wherein the step of removing the insulation includes

placing the fabric incorporating the conductors or sections between a surface and a masking device, and

removing insulation at the point of overlap of the conductors or sections identified through the masking device;

bringing the conductors into contact with each other at a junction point; and

forming a bond between the conductors at the junction point.

2. The method of claim 1, wherein the step of removing the insulation includes dispensing a solvent through the masking device.

3. The method of claim 1, wherein the conductors include a conductive fiber and a connector.

4. The method of claim 1, wherein the masking device is patterned with a via at the intersection of the two conductors.

5. The method of claim 1, wherein the fabric comprises a computer-generated pattern of intersecting conductive fibers and the masking device comprises a computer-generated pattern with multiple vias that correspond to the pattern of intersecting conductive fibers in the fabric.

6. The method of claim 1, wherein the masking device comprises a material chosen from screen-printing material, plastic, and metal.

7. The method of claim 1, wherein the step of bringing the conductors into contact with each other at a junction point comprises at least one of chemical bonding, laser light application, ultrasonic welding, and combinations thereof.

8. The method of claim 1, wherein the step of bringing the conductors into contact with each other at a junction point comprises:

placing fabric incorporating the conductors between an anvil and a sonotrode;

aligning a desired junction point of the conductors at the contact point of the anvil and sonotrode; and

subjecting the conductors to ultrasonic vibrations while pressing the sonotrode and anvil into contact at the junction point.

9. The method of claim 1, further comprising identifying pre-selected points of junction between the two conductors.

10. The method of claim 1, wherein the fabric is already woven or knitted.

11. The method of claim 1, wherein the method is carried out during formation of the fabric.

12. The method of claim 1, wherein forming a bond between the conductors at the junction point comprises:

creating intense friction between the conductors, thereby exciting the conductors;

breaking atomic bonds within each individual conductor; and

triggering atomic binding forces between the two conductors.

13. The method of claim 1, further comprising the step of depositing a conductive paste at the junction point of the two conductors.

14. The method of claim 1, wherein the method is performed off-line after fabrication of the fabric.