Self-healing electrical communication paths

• US 8,063,307 B2
• Filed: 11/17/2008
• Issued: 11/22/2011
• Est. Priority Date: 11/17/2008
• Status: Active Grant

• Current Assignee: Mercury Mission Systems LLC (Mercury Systems, Incorporated)
• Original Assignee: Physical Optics Corporation
• Inventors: Pradhan, Ranjit, Bukshpun, Leonid, Lee, Kang S., Forrester, Thomas, Jannson, Tomasz
• Primary Examiner(s): Nguyen; Chau
• Application Number:
  US12/272,616
• Publication Number:
  US 20100122832A1
• Time in Patent Office: 1,100 Days
• Field of Search: 174/102.SC, 174/120.SC, 174/117.F
• US Class Current: 174/102.SC
• CPC Class Codes: A41D 1/005 with embedded cable or connector

Abstract

Self-healing electrical garments and self-healing electrical conductors and components for use in electrical garments are provided. A communication medium of various forms is integrated into a garment seam that is used to join two or more portions of a garment. The communication media can be used to provide electrical or other electromagnetic connection for coupling among a plurality of electrical devices associated with the garment. The self-healing electrical conductor may be used as part of a garment portion or may be used as a joining fiber in a variety of techniques to join garment portions together. The self-healing electrical conductor comprises an electrical conductor, a conductive polymer immediately surrounding or adjacent to the electrical conductor, an insulator enclosing the electrical conductor and the conductive polymer.

Claims

1. A self-healing conductor, comprising:

an electrical conductor;

an uncured electrically conductive viscous material disposed adjacent the electrical conductor; and

an enclosure at least partially enclosing the electrically conductive viscous material.

2. The self-healing conductor of claim 1, wherein the electrical conductor is comprised of a conducting material.

3. The self-healing conductor of claim 1, wherein the electrical conductor is comprised of a semi-conducting material.

4. The self-healing conductor of claim 1, wherein the uncured electrically conductive viscous material is a self-curing conductive polymer.

5. The self-healing electrical conductor of claim 1, wherein the self-curing conductive polymer increases in viscosity upon exposure to air.

6. The self-healing conductor of claim 1, further comprising a curing agent and wherein the electrical conductor, conductive polymer, and curing agent are adjacent to one another but not concentric.

7. The self-healing electrical conductor of claim 1, wherein the electrical conductor, electrically conductive viscous material, and curing agent are disposed in at least one channel adjacent to the electrical conductor.

8. The self-healing electrical conductor of claim 1, wherein a viscosity of the uncured electrically conductive viscous material is selected based on a distance between the electrically conductive viscous material and the electrical conductor.

9. The self-healing electrical conductor of claim 1, wherein the uncured electrically conductive viscous material comprises carbon nanotubes.

10. A self-healing conductor, comprising:

an electrical conductor;

an uncured electrically conductive viscous material adjacent the electrical conductor;

a curing agent adjacent to but separated from the electrically conductive viscous material

a first enclosure at least partially enclosing the uncured viscous electrically conductive material; and

a second enclosure at least partially enclosing the curing agent.

11. The self-healing conductor of claim 10, wherein the electrical conductor is ring-shaped.

12. The self-healing conductor of claim 11, wherein the conductive polymer and curing agent are disposed within the ring-shaped conductor.

13. The self-healing conductor of claim 11, wherein the curing agent is disposed within the ring conductor and the conductive polymer is contained within containers distributed within the curing agent.

14. The self-healing conductor of claim 10, wherein the conductive polymer is disposed in the center of the ring-shaped conductor.

15. The self-healing conductor of claim 10, wherein the conductive polymer is contained in containers distributed within the curing agent.

16. The self-healing conductor of claim 10, wherein the conductive polymer is ring-shaped.

17. The self-healing conductor of claim 16, wherein the ring-shaped conductive polymer contains containers of the curing agent.

18. The self-healing conductor of claim 10, wherein the electrical conductor, uncured electrically conductive viscous material, and curing agent are adjacent to one another but not concentric.

19. The self-healing electrical conductor of claim 10, wherein the uncured electrically conductive viscous material, and curing agent are disposed in at least one channel formed by the first and second enclosures and adjacent to the electrical conductor.

20. A multi-layer self-healing electrical conductor, comprising

an electrical conductor;

an electrically conductive viscous material disposed adjacent the electrical conductor; and

an enclosure at least partially enclosing the electrically conductive viscous material; and

wherein the electrical conductor is disposed in a first layer of the multi-layer conductor; and

the electrically conductive viscous material is disposed in a second layer adjacent the first layer containing the electrical conductor;

wherein the second layer comprises an insulator at least partially enclosing the viscous electrically conductive material.

21. The self-healing electrical conductor of claim 20, further comprising an insulating layer disposed between the first and second layers.

22. The self-healing electrical conductor of claim 20, wherein the first and second layers are positioned such that a cut or break in the first and second layers severing the electrical conductor and severing the enclosure at least partially enclosing the electrically conductive viscous material allows the electrically conductive viscous material to flow to the first layer and cure, thereby providing a conductive path in the electrical conductor bridging the cut or break.

23. The self-healing electrical conductor of claim 20, further comprising a curing agent layer disposed in a third layer adjacent the second layer containing the electrically conductive viscous material.

24. The self-healing electrical conductor of claim 23, further comprising a barrier layer disposed between the second and third layers.

25. The self-healing electrical conductor of claim 20, wherein the enclosure comprises a plurality of discrete wells and the electrically conductive viscous material is disposed in the wells.

26. The self-healing electrical conductor of claim 20, further comprising a curing agent layer disposed in a third layer adjacent the second layer containing the electrically conductive viscous material;

wherein the second layer comprises a plurality of discrete first wells and the electrically conductive viscous material is disposed in the first wells; and

wherein the third layer comprises a plurality of discrete second wells and the curing agent is disposed in the second wells.

27. The self-healing electrical conductor of claim 26, further comprising a barrier layer between corresponding ones of the first and second wells and wherein the first and second wells are positioned with respect to the electrical conductor such that a cut or break in the first, second and third layers and the barrier layer allows the electrically conductive viscous material to mix with the curing agent and flow to the first layer and cure, thereby providing a conductive path in the electrical conductor bridging the cut or break.

28. A multi-layer self-healing electrical conductor, comprising:

an electrical conductor;

an electrically conductive viscous material adjacent the electrical conductor;

a curing agent adjacent to but separated from the electrically conductive viscous material

a first enclosure at least partially enclosing the viscous electrically conductive material; and

a second enclosure at least partially enclosing the curing agent; and

wherein the electrical conductor is disposed in a first layer of the multi-layer conductor;

the electrically conductive viscous material is disposed in a second layer adjacent the first layer containing the electrical conductor;

the curing agent is disposed in a third layer adjacent to the second layer; and

wherein the self-healing electrical conductor further comprises a barrier layer between the second and third layers.

29. The self-healing electrical conductor of claim 28, further comprising an insulating layer disposed between the first and second layers.

30. The self-healing electrical conductor of claim 28, wherein the first and second layers are positioned such that a cut or break in the first, second, third and barrier layers, severing the electrical conductor and releasing the electrically conductive viscous material and curing agent, allows the electrically conductive viscous material to flow to the first layer and cure, thereby providing a conductive path in the electrical conductor bridging the cut or break.

31. The self-healing electrical conductor of claim 28, further comprising a barrier layer disposed between the second and third layers.

32. The self-healing electrical conductor of claim 28, wherein the first and second enclosures comprise a first and second plurality of discrete wells.

33. The self-healing electrical conductor of claim 32, further comprising a barrier layer between corresponding wells of the first and second pluralities of wells and wherein the wells are positioned with respect to the electrical conductor such that a cut or break in the first, second and third layers and the barrier layer allows the electrically conductive viscous material to mix with the curing agent and flow to the first layer and cure, thereby providing a conductive path in the electrical conductor bridging the cut or break.