Electrical components and circuits constructed as textiles

• US 8,298,968 B2
• Filed: 02/25/2005
• Issued: 10/30/2012
• Est. Priority Date: 02/27/2004
• Status: Expired due to Fees

• Current Assignee: Intelligent Textiles Limited
• Original Assignee: Intelligent Textiles Limited
• Inventors: Swallow, Stanley Shigezo, Peta-Thompson, Asha
• Primary Examiner(s): Choi, Peter Y
• Application Number:
  US10/598,373
• Publication Number:
  US 20080233822A1
• Time in Patent Office: 2,804 Days
• Field of Search: 442/181, 442/229, 442/228, 345/173, 345/174
• US Class Current: 442/229
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• 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 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D10B 2101/20 Metallic fibres
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2211/04 Silk
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: D10B 2403/02431 with electronic components, e.g. sensors or switches
• CPC Class Codes: H01H 2203/0085 Layered switches integrated into garment, clothes or textile
• CPC Class Codes: H01H 2203/01 Woven wire screen
• 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: 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 442/3382 Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/339 Metal or metal-coated strand

Abstract

Electrical components are formed in a fabric during the weaving process by a series of crossing conductors in the warp and weft fibers of the fabric. Some of the crossing points provide permanent Separation of the crossing conductors, others permanent connection of the crossing conductors and others connection upon the application of pressure to the fabric. The structure provides the possibility of forming a greater range of components and more reliable component characteristics than heretofore possible.

Claims

1. A fabric having a woven construction, including in its woven construction a plurality of spaced first elongated electrically conductive filaments or fibres and a plurality of spaced second elongated electrically conductive filaments or fibres, said first elongated electrically conductive filaments or fibres being crossed by said second elongated electrically conductive filaments or fibres at a plurality of crossover points,

wherein said plurality of crossover points consists of at least one instance of a crossover point at which the first and second electrically conductive filaments or fibres are permanently biased apart and at least one instance of a crossover point at which said corresponding first and second electrical conductors are permanently physically connected together,

wherein said permanently connected crossover points and said permanently biased apart crossover points bring into being at least one conductive path within said fabric that is composed of two or more contiguous segments of two or more electrically conductive filaments or fibres;

and

wherein either;

(a) the conductive path is arranged in series along a spiral path;

or

(b) the fabric includes a parallel structure comprised of a multitude of parallel sub-paths, the conductive path being defined by comb shapes conductively isolated from each other, with the fingers of the combs being interlaced.

2. A fabric as claimed in claim 1, including insulating warp fibres neighbouring an electrically conductive filament or fibre in the warp, wherein the neighbouring insulating warp fibres to an electrically conductive filament or fibre in the warp include a warp float over or under more than one weft yarn.

3. A fabric as claimed in claim 1, including insulating weft fibres neighbouring an electrically conductive filament or fibre in the weft, wherein the neighbouring insulating weft fibres to an electrically conductive filament or fibre in the weft include a weft float over or under more than one warp yarn.

4. A fabric as claimed in claim 1, wherein the two or more contiguous segments are of two or more electrically conductive filaments or fibres that exhibit differing linear resistivities.

5. A fabric as claimed in claim 1, wherein the fabric provides an electrical heating element that exhibits a heterogeneous distribution of heated power dissipation along the resultant conductive path and/or across the fabric.

12. The fabric of claim 1 wherein the conductive path within the fabric includes:

a. multiple electrically conductive filaments or fibres connected in parallel, and

b. terminal lengths of electrically conductive filaments or fibres extending therefrom,

with the number of parallel filaments or fibres being at least an order of magnitude greater than the number of electrically conductive filaments or fibres defining terminal lengths of the conductive path.

14. A fabric as claimed in claim 1, wherein the fabric includes a warp and a weft, the warp including at least one of said first electrically conductive filaments or fibres and the weft including at least one of said second electrically conductive filaments or fibres.

15. A fabric as claimed in claim 1, including insulating fibres or filaments which bias said first and second electrically conductive filaments or fibres apart at said permanently biased apart crossover points.

16. A fabric as claimed in claim 15, wherein the woven construction includes yarn and wherein the first and/or second electrically conductive filaments or fibres are subject to a warp and/or weft float over or under more than one yarn to effect the biasing apart of first and second electrically conductive filaments or fibres at said permanently biased apart crossover points.

17. A fabric as claimed in claim 1, wherein said one or more permanently connected crossover points are effected by means of a plain weave structure local to that crossover point.

18. A fabric as claimed in claim 1, wherein the contiguous segments of electrically conductive filaments or fibres have a length and/or number and/or linear resistivity chosen so as to constitute one or more resultant conductive paths that conform to a required electrical characteristic and/or a required value of electrical property.

19. A fabric as claimed in claim 18, wherein the electrical property is selected from the group consisting of electrical resistance, capacitance, inductance, impedance and reactance.

20. A fabric as claimed in claim 18, wherein the electrical characteristic is a heterogeneous distribution of resistance along the resultant conductive path and/or across the fabric.

6. A fabric having a woven construction with a warp and a weft, the fabric including:

I. several spaced elongated first electrically conductive elements included in the warp of the fabric;

II. several spaced elongated second electrically conductive elements included in the weft of the fabric, and crossing the first electrically conductive elements at several crossover points; and

III. elongated insulating elements in the warp and/or the weft of the fabric, wherein the crossover points consist of;

A. one or more crossover points at which the first and second electrically conductive elements are permanently biased apart, the permanent biasing being effected by warp and/or weft floats of the first and/or second electrically conductive elements over or under more than one of the elongated insulating elements, and

B. one or more crossover points at which the first and second electrically conductive elements are permanently in conductive communication, the permanent conductive communication being effected by a plain weave in the warp and weft at the crossover point,

wherein the permanently biased apart crossover points and the crossover points in permanent conductive communication generate at least one conductive path within the fabric that includes two or more contiguous segments of two or more of the electrically conductive elements, the contiguous segments together having one or more of;

(1) a length,

(2) a number, and/or

(3) a linear resistivity,

and wherein either;

(a) the conductive path is arranged across two or more of the electrically conductive elements in series along a spiral path, or

(b) the conductive path includes interdigitated subpaths conductively isolated from each other,

the conductive path thereby providing desired electrical characteristics.

7. The fabric of claim 6 wherein the warp includes:

a. elongated insulating elements, and

b. an elongated electrically conductive element neighboring the elongated insulating elements,

wherein the insulating elements include a warp float over or under more than one of the elements in the weft.

8. The fabric of claim 6 wherein the weft includes:

a. elongated insulating elements, and

b. an elongated electrically conductive element neighboring the elongated insulating elements,

wherein the insulating elements include a weft float over or under more than one of the elements in the warp.

9. The fabric of claim 6 wherein the two or more contiguous segments of two or more of the electrically conductive elements include electrically conductive elements having different linear resistivities.

10. The fabric of claim 6 wherein the desired electrical characteristics include one or more of:

a. resistance,

b. capacitance,

c. inductance,

d. impedance, and

e. reactance.

11. The fabric of claim 6 wherein the desired electrical characteristics include a heterogeneous distribution of resistance along one or more of:

a. the conductive path, and

b. the entire fabric.

13. The fabric of claim 6 wherein the conductive path within the fabric includes:

a. multiple electrically conductive filaments or fibres connected in parallel, and

b. terminal lengths of electrically conductive filaments or fibres extending therefrom,

with the number of parallel elements being at least an order of magnitude greater than the number of electrically conductive elements defining terminal lengths of the conductive path.