Plural layer woven electronic textile, article and method Number:7,144,830 from the United States Patent and Trademark Office (PTO) owispatent

Title: Plural layer woven electronic textile, article and method

Abstract: A woven article having plural weave layers 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. An electrical function is provided by one or more circuit carriers disposed in cavities in the plural layer woven article and/or one or more functional yarn in the warp and/or the weft, wherein the circuit carrier and/or functional yarn include an electrical contact for connecting to the electrically conductive yarn in the warp and/or weft.

Patent Number: 7,144,830 Issued on 12/05/2006 to Hill,   et al.

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Inventors:	Hill; Ian Gregory (Mercer, NJ), Trotz; Seth (Littleton, MA), Riddle; George Herbert Needham (Princton, NJ), Brookstein; David Stuart (Fort Washington, PA), Govindaraj; Muthu (Harleysville, PA)
Assignee:	Sarnoff Corporation (Princeton, NJ)
Appl. No.:	10/431,763
Filed:	May 8, 2003

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Current U.S. Class:	442/205 ; 442/206; 442/207; 442/301
Current International Class:	D03D 11/00 (20060101)
Field of Search:	442/181,185,186,205-207

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References Cited [Referenced By]

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Primary Examiner: Juska; Cheryl A.
Assistant Examiner: Sperty; Arden B.
Attorney, Agent or Firm: Lowenstein Sandler PC

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Parent Case Text

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This Application claims the benefit of U.S. Provisional Application Ser. No. 60/379,723 filed May 10, 2002, and of U.S. Provisional Application Serial No. 60/419,159 filed Oct. 17, 2002.

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Claims

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What is claimed is:

1. A multilayer woven article having a warp and a weft, and defining an electrical circuit, said multilayer woven article comprising: a plurality of electrically insulating yarns and uninsulated electrically conductive yarns in the warp; a plurality of electrically insulating yarns and uninsulated electrically conductive yarns in the weft interwoven with said plurality of electrically insulating yarns and uninsulated electrically conductive yarns in the warp in a weave defining plural layers of said woven article; wherein an uninsulated electrically conductive yarn in the warp crossing an uninsulated electrically conductive yarn in the weft makes electrical connection therewith at the crossing thereof; and at least one uninsulated electrically conductive yarn in the warp and/or in the weft woven into at least a first layer and a second layer of the plural layers for crossing at least one uninsulated electrically conductive yarn in the other of the warp and/or weft without making electrical contact therewith; whereby a multilayer woven article is provided wherein uninsulated electrically conductive yarn disposed in the warp and weft are woven so as to connect at certain crossings when in the same one of the plural layers and to not connect at other crossings when not in the same one of the plural layers to define an electrical circuit.

2. The multilayer woven article of claim 1 wherein said plurality of electrically insulating yarns and/or electrically conductive yarns includes at least one electrically conductive yarns in the warp in electrical contact with at least one electrically conductive yarn in the weft at a crossing thereof without mechanically attaching the electrically conductive yarn thereat.

3. The multilayer woven article of claim 1 further comprising: at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn, 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 of said at least one functional yarn and at least one uninsulated electrically conductive yarn in the other of the warp and the weft cross for providing at the crossing an electrical connection between the electric device and the at least one uninsulated electrically conductive yarn.

4. The multilayer woven article of claim 1 further comprising electrically insulating yarns woven in a third layer intermediate the first and second layers of the plural layers for interposing an insulating layer between uninsulated electrically conductive yarns in the first and second layers of the plural layers.

5. A method for weaving a fabric and/or a textile electrical circuit article having a warp and a weft comprising: providing a plurality of electrically insulating yarns and uninsulated electrically conductive yarns in the warp; weaving a plurality of electrically insulating yarns, and uninsulated electrically conductive yarns in the weft with said plurality of electrically insulating yarns and uninsulated electrically conductive yarns in the warp; wherein said weaving defines plural layers of the electrical circuit article; wherein an uninsulated electrically conductive yarn in the warp crossing an uninsulated electrically conductive yarns in the weft in the same layer of the plural layers makes electrical connection therewith at the crossing thereof; and weaving at least one uninsulated electrically conductive yarn in the warp and/or in the weft into at least a first layer and a second layer of the plural layers for crossing at least one uninsulated electrically conductive yarn in the other of the warp and/or well without making electrical contact therewith; whereby a woven electrical circuit article is provided wherein electrically conductive yarn disposed in the warp and the weft are woven so as to connect at certain crossings when in the same one of the plural layers and to not connect at other crossings when not in the same one of the plural layers.

6. The method of claim 5 wherein said weaving a plurality of electrically insulating yarns and/or electrically conductive yarns includes controlling a tightness of the weave and/or a density of yarn for maintaining at least one electrically conductive yarn in the warp in electrical contact with at least one electrically conductive yarn in the weft at a crossing thereof without mechanically attaching the electrically conductive yarns thereat.

7. The method of claim 5 further comprising: weaving at least one functional yarn in one of the warp and the weft adjacent an electrically insulating yarn, 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 between the electronic device and the at least one electrically conductive yarn.

8. The method of claim 7 wherein said weaving a plurality of electrically insulating yarns and/or electrically conductive yarns 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.

9. The multilayer woven article of claim 1 wherein at least two of the plural layers define at least one cavity there between and wherein at least one of the two layers defining the at least one cavity has at least one of the uninsulated electrically conductive yarns adjacent the at least one cavity, said woven article further comprising: a circuit carrier having at least one exposed electrical contact, said circuit carrier including at least one electronic device connected to the electrical contact for performing a function, and wherein said circuit carrier is disposed in the at least one cavity with its at least one exposed electrical contact in electrical connection with said at least one of the uninsulated electrically conductive yarns.

10. The method of claim 5 wherein said weaving defines at least one cavity between the first and second layers, and wherein at least one of the first and second layers defining the at least one cavity has at least one of the uninsulated electrically conductive yarns adjacent the at least one cavity, said method further comprising: placing a circuit carrier in the at least one cavity, wherein the circuit carrier includes exposed electrical contacts providing electrical connection between an electronic device in the circuit carrier and the at least one of the uninsulated electrically conductive yarns in the warp and/or the weft that is woven in the at least one of the first and second layers defining the at least one cavity.

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Description

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The present invention relates to a woven article and method, and, in particular, to a plural layer woven textile and/or article having an electronic circuit woven therein, and a method therefor.

In many fields of endeavor, from military to sport to apparel, a desire exists for electronic circuits to be incorporated into fabric and into articles that may be made of fabric. In some instances, such as electric blankets and electrically conductive fabric, electrically resistive and/or electrically conductive are been woven into fabric with insulating yarn to provide the desired resistance heating and/or conductivity characteristics. In these relatively simple arrangements, the characteristics of the resistive heating yarn determines the heating characteristics of the woven electric blanket and the conductivity of the electrically conductive yarn substantially determines the conductivity characteristic of the fabric. In other words, the number and size of electrically conductive yarn determine the conductivity of the fabric.

Apart from the aforementioned relatively simple arrangements, where electrical functionality of greater complexity has been desired, electrical circuits have been added to fabric after the fabric is woven. Among the approaches are the lamination of electrical circuit substrates to a fabric, e.g., as described in U.S. Patent Publication No. US 2002/0076948 of B. Farrell et al. entitled "Method of Manufacturing a Fabric Article to Include Electronic Circuitry and an Electrically Active Textile Article," and the embroidering and/or applique of electrical conductors and circuits onto a fabric, e.g., as described in U.S. Pat. No. 6,210,771 to E. R. Post et al. entitled "Electrically Active Textiles and Articles Made Therefrom" and in an article by E. R. Post et al. entitled "E-Broidery: Design and Fabrication of Textile-Based Computing" published in the IBM Systems Journal, Volume 39, Numbers 3 & 4, pages 840 860, 2000. In addition, an arrangement attaching electrical components to woven fabric including conductive yarn, such as by connecting the components to the conductive yarn by soldering and/or by electrically conductive adhesive, is described in U.S. Pat. No. 6,381,482 to Jayaraman et al. entitled "Fabric or Garment With Integrated Flexible Information Infrastructure."

In the aforementioned arrangements, the electrical electronic function is added after the fabric has been woven, e.g., by embroidery or by applique or by mechanical attachment, thereby adding additional steps and additional complexity to the manufacturing process. In addition, the particular arrangement thereof appears to be suited to one specific application or usage with corresponding specific manufacturing, and does not appear to lend itself to an efficient, relatively general manufacturing wherein the function and operation of the resulting fabric need not be specified or determined until after the fabric is woven, i.e. manufactured.

Accordingly, there is a need for a woven textile and article having an electronic circuit function woven therein.

To this end, the multilayer woven article of the present invention comprises warp yarn and weft yarn interwoven in a multilayer weave having plural layers defining at least one cavity therebetween, at least one electrically conductive yarn disposed in the warp and/or in the weft and having a portion thereof in one of the plural layers defining the at least one cavity, and a circuit carrier disposed in the cavity and having at least one exposed electrical contact in electrical connection with the at least one electrically conductive yarn, the circuit carrier including at least one electronic device for performing a function.

According to another aspect of the invention, a multilayer woven article comprises a plurality of electrically insulating yarn and electrically conductive yarn defining plural layers in the warp, a plurality of electrically insulating yarn and electrically conductive yarn in the weft interwoven in a multilayer weave with the plurality of electrically insulating yarn and electrically conductive yarn in plural layers in the warp, wherein an electrically conductive yarn in the warp crossing an electrically conductive yarn in the weft makes electrical connection therewith at the crossing thereof; and at least one electrically conductive yarn in the warp and/or in the weft woven into at least first and second ones of the plural layers for crossing at least one electrically conductive yarn in the other of the warp and/or weft without making electrical contact therewith.

BRIEF DESCRIPTION OF THE DRAWING

The detailed description of the preferred embodiments of the present invention will be more easily and better understood when read in conjunction with the FIGURES of the Drawing which include:

FIG. 1A is a plan view schematic diagram of an example woven fabric including an example embodiment of an electronic circuit therein;

FIG. 1B is an isometric schematic view of a portion of an example multilayer woven fabric including an example embodiment of an electronic circuit therein;

FIG. 2 is a plan view schematic diagram of a yarn including an example electronic circuit function, as for the woven fabric of FIGS. 1A and 1B;

FIGS. 3A through 3D are plan view schematic diagrams of example embodiments of yarns including an example electronic circuit function suitable for a woven fabric as illustrated in FIGS. 1A and 1B;

FIGS. 4A, 4B and 4C are plan view schematic diagrams of an example embodiment of a circuit carrier including an example electronic circuit function suitable for a woven fabric as illustrated in FIGS. 1A and 1B, and FIG. 4D is an isometric view thereof when folded;

FIG. 5 is a partial cross-sectional schematic diagram illustrating an example circuit carrier disposed in a cavity of a multilayer woven fabric;

FIGS. 6A and 6B are schematic diagrams illustrating example loom arrangements suitable for making example embodiments of fabric described herein;

FIG. 7 is a schematic diagram of an example carrier insertion arrangement and an example roller arrangement suitable for weaving and finishing fabric woven in accordance with FIGS. 6A 6B;

FIG. 8 is a schematic diagram of an example yarn including an example electronic circuit function suitable for use with the example loom arrangements of FIGS. 6A 6B; and

FIG. 9 is a schematic diagram of an example woven textile illustrating an ordinary weave and a complex weave useful in connection with the arrangements of FIGS. 1A to 3B.

In the Drawing, where an element or feature is shown in more than one drawing figure, the same alphanumeric designation may be used to designate such element or feature in each figure, and where a closely related or modified element is shown in a figure, the same alphanumerical designation primed may be used to designate the modified element or feature. It is noted that, according to common practice, the various features of the drawing are not to scale, and the dimensions of the various features are arbitrarily expanded or reduced for clarity.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Woven textiles generally comprise two sets of relatively straight yarn, the warp and the weft, which cross and interweave to form a fabric. Typically, the warp and weft yarn cross at approximately a right angle as woven, but may cross at any angle. Also typically, fabric is woven to have a given width, but may have any desired length. The warp yarn runs in the length direction of the fabric, which is generally the longer dimension thereof, and the weft yarn runs in the crosswise or width direction thereof, which is generally the shorter dimension. With a modern computer controlled loom, the weaving process is performed automatically and may be responsive to weaving instructions described in computer instructions and/or derived from a computer aided design program. More complex weaves, such as a Leno weave in which a pair of warp yarn are intertwined in a series of figure eights with filling yarn, may employ more than two sets of yarn and/or other than a plain weave in the warp and/or weft, are readily made by such modern looms.

A textile and/or fabric may be woven in a single-layer weave and/or in a plural-layer weave. It is noted that textiles and/or fabrics having two or more layers, i.e. plural layers, are commonly and generally referred to as multilayer weaves. Certain weaves may be referred to specifically, e.g., a two-layer woven fabric may be referred to as a double weave. Double and other multilayer weaving is conventional and is described in many publications, e.g., D. Chandler, Learning to Weave, Interweave Press, 1995, Lesson 10, "Double Weave."

In a plural layer (multilayer) weave, warp yarn are designated as being in one of two or more layers and the weft yarn is interwoven with warp yarn in any one or more layers, so as to weave fabrics having other than a single-layer sheet-like construction. One or more layers, tubes, pockets, cavities, or other complex woven structures may be provided utilizing multilayer weaving, e.g., by providing one or more regions wherein two overlying layers of weave are not interwoven in the region(s) and the one or more regions are interspersed among and surrounded by regions wherein the multiple layers are interwoven. Any and all of such regions wherein plural layers are not interwoven may be referred to as "pockets" for simplicity, or generically and formally as "cavities."

The yarn, which is typically long, flexible and relatively thin, is selected to provide the desired strength, wear, laundering, durability and other requirements of the end use to which the fabric is intended to be put. Where ones of the warp and/or weft yarn are electrically conductive, the woven fabric may function in a manner akin to an electrical circuit board, i.e. the electrically conductive yarn provide electrical connections between various locations of the woven fabric, and/or to locations external to the fabric, and/or with electrical and/or electronic components embodied in the fabric, as may be desired.

The embodiments of woven textile and/or fabric herein generally include a carrier including an electronic circuit for performing all or part of an electronic function. Examples of such carriers include circuit carriers, also referred to as carriers, modules or "circuit tablets" in some cases, and "functional yarn."

A circuit carrier is a relatively compact part including one or more electronic parts and/or devices and interconnections therebetween, and that also has one or more exposed contacts at which electrical connection to conductive yarn in a textile or fabric may be made. One or more circuit carriers may be placed into cavities formed in a woven textile or fabric, e.g., as by weaving a pocket, tube, or other cavity by plural layer or multilayer weaving. The arrangements herein include circuit carriers in a woven textile or fabric that has one or more electrically conductive yarn in the warp and/or the weft.

Another example of a circuit carrier is referred to herein as a "functional yarn" which may be in the warp and/or the weft, but is typically in the weft. Functional yarn includes an elongated electrical and/or electronic substrate on which are disposed one or more electrical conductors and a plurality of electrical and/or electronic devices that connect to one or more of the electrical conductors. In other words, a functional yarn is any electrical and/or electronic substrate that includes electrical conductors and electrical and/or electronic devices that perform an electrical and/or electronic function, wherein the substrate may be utilized as a yarn and woven.

FIG. 1A is a plan view schematic diagram of an example woven fabric 100 including an example embodiment of an electronic circuit, and FIG. 2 is a plan view schematic diagram of a yarn 150 including an example electronic circuit function, as for the woven fabric of FIGS. 1A and 1B. Fabric 100 is a plain weave fabric including insulating yarn 110 and electrically conductive yarn 120 in the warp and insulating yarn 130 and functional yarn 150 in the weft. Fabric 100 may also include electrically conductive yarn in the weft. Insulating yarn 110 are disposed between adjacent electrically conductive yarn 120 in the warp to provide an insulating separator therebetween and insulating yarn 130 are disposed between adjacent functional yarn 150 (and/or electrically conductive yarn, if any) in the warp to provide an insulating separator therebetween.

FIG. 1B is an isometric schematic view of a portion of an example multilayer woven fabric 100' including an example embodiment of an electronic circuit. Example fabric 100' is a multilayer weave fabric, specifically a three-layer weave, including, e.g., insulating yarn 110 and electrically conductive yarn 120 in the warp of each of layers 101 and 103, and including, e.g., insulating yarn 130, electrically conductive yarn 140 and functional yarn 150 in the weft. Example layer 102 includes insulating yarn 110, 130 in the warp and weft so as to provide an insulating separation between the conductive yarn 120, 140 disposed in layers 101 and 103. Layer 102 may include electrically conductive yarn 120 and/or functional yarn 150 in the warp, but electrically conductive warp yarn 120 and/or functional yarn 150 may be included only where not proximate conductive warp yarn 120 in either or both of layers 101 and/or 103 so as to avoid short circuits. Example fabric 100' may include functional yarn 150 in the warp and/or in the weft. Insulating yarn 110 are disposed between adjacent electrically conductive yarn 120 in the warp to provide an insulating separator therebetween and insulating yarn 130 are disposed between adjacent functional yarn 150 and/or electrically conductive yarn 140 in the warp to provide an insulating separator therebetween.

Ones of the weft yarn, e.g., ones of weft yarn 130, 140, 150, are interwoven with ones of warp yarn 110, 120 (and with ones of warp functional yarn 150, if any) in warp layers 101, 102, 103, to weave a multilayer fabric. In the fabric portion illustrated, one warp yarn 140a is interwoven with layers 101, 102 and 103 and another warp yarn 140b is interwoven with layers 102 and 103. The combination of multilayer interwoven electrically conductive yarn 120 and/or functional yarn 150 in the warp and electrically conductive yarn 140 and/or functional yarn 150 in the weft provide a multilayer structure having electrical conductors and/or functions on one or more layers, thereby to provide an electrical structure somewhat analogous to the structure of a multilayer laminated electronic printed circuit board.

It is noted that while known electrically conductive yarn is completely uninsulated, partially insulated electrically conductive yarn could be employed in the textiles, fabrics and/or articles described herein, wherein the uninsulated portions thereof are woven to be in locations whereat electrically connection is to be made thereto, e.g., at crossings of other electrically conductive yarn and/or of functional yarn to which electrical connection is to be made. As used herein, the terms electrically conductive yarn and uninsulated electrically conductive yarn are used interchangeably to refer to electrically conductive yarn that is completely or partially uninsulated.

Interweaving of plural adjacent weft yarn, typically insulating yarn 130 and electrically conductive yarn 140 between two or more warp layers 101, 102, 103, can be woven to form pockets, tubes or recesses, e.g., as suggested by cavities 106a, 106b, into which circuit carriers may be placed. Preferably, cavities 106 are woven to be closed pockets and the circuit carriers are inserted into the pockets during the weaving process and are enclosed therein as the pockets are woven, as described below. Typically, adjacent layers are interlocked by weft yarn 130, 140, however, they can be woven as separate layers, as they are to form a cavity or pocket as described. An external or surface layer wholly of insulating yarn may be woven as an outer layer so as to provide insulation of the conductive yarn 120, 140 and functional yarn 150 included in the inner (enclosed or internal) layers.

Functional yarn 150 of FIG. 2 includes plural electrical conductors 154, 156, 158 and an electronic device 160 on an insulating electrical or electronic substrate 152. In the specific example of FIGS. 1 and 2, electronic device 160 is a light emitting diode (LED) 160 that emits light in response to electrical signals applied thereto. Substrate 152 is an elongate strip of flexible insulating material, e.g., a polyimide or polyester or other material suitable for use as an electrical substrate. Conductors 154 158 are formed on substrate by any suitable means, such as by etching a conductive metal layer, e.g., copper layer, attached to substrate 152 using known methods for making flexible electrical printed circuits and the like. As illustrated, conductor 154 extends substantially the length of substrate 152 to provide a common connection to all of the LEDs 160 thereon, and an electrical signal for activating LEDs 160 is applied thereto. Conductor 158 provides an electrical contact 158 to which an electrical signal for activating LED 160 is applied, and each contact 158 is connected to a corresponding LED 160 by a conductor 156.

Electrical connection between electrically conductive yarn 120 in the warp and functional yarn 150 and/or electrically conductive yarn in the weft is satisfactorily made by the physical contact therebetween in a plain weave having a typical tightness and/or density of yarn, without any mechanical attaching thereof. Optionally, the electrical connection provided by physical contact, e.g., frictional contact, may be supplemented, e.g., by a mechanical attaching such as a spot of electrically conductive adhesive or solder, at each connection 158. For proper electrical contact, functional yarn 150 is registered so that contacts 158 thereon each underlie a conductive yarn 120 where they cross. To this end, functional yarn 150 may include one or more registration marks or indicia 180 at one end thereof so that the loom may sense the position thereof in the weaving process to provide proper registration.

Optionally, conductor 154 and/or contacts 158 may be coated with an insulating coating, except at locations where an electrical connection is to be made thereto. Also optionally, conductor 154 and/or contacts 158 may have a spot of electrically conductive adhesive applied at locations where an electrical connection is to be made thereto, e.g., at the terminal locations for LEDs 160 and/or at intersections with conductive yarn 120. LEDs 160 may be connected to substrate 152 by any suitable means, e.g., by soldering or electrically conductive adhesive.

Each LED 160 is illuminated by applying a suitable electrical signal between common conductor 154 and the contact 158 associated with the LED. In fabric 100, each conducting yarn 120 intersects functional yarn 150 to overlie one of the contacts 158 thereof. Thus, each LED 160 has one terminal that is connected via contact 158 to a conductive yarn 120 that is accessible at an edge of fabric 100 and has a terminal connected to conductor 154 that is accessible at another edge of fabric 100, and so each LED 160 may be activated by applying an electrical signal to the appropriate ones of conductive yarn 120 and conductors 154. LEDs 160 of fabric 100 are in aggregate an addressable passive-matrix display having row conductors 120 and column conductors 154 by which any one or more of LEDs 160 may be addressed. Alternatively and optionally, a current-limiting resistor R could be provided for each LED 160 or for groups of LEDs 160, of functional yarn 150.

Fabric 100 as described is a woven passive-matrix display wherein any pattern of the LEDs 160 may be illuminated by applying appropriate electrical signals between selected ones of conductors 120 and 154. However, with additional conductors and/or electronic devices on functional yarn 150, an active-matrix display and/or a non-matrix display and/or a display having individually addressable pixels (LEDs) may be provided, as described below. Thus, LEDs 160 or any other electronic devices 160 may be energized and/or operated in a programmed pattern and/or sequence, e.g., to provide an alphanumeric or other character display, or a pixilated display, or to provide a sensor array fabric that sequentially senses different agents and/or processes the sensed data.

It is noted that in an actual application, e.g., a textile or textile article, fabric 100 would likely be much larger and would contain many more yarn of one or more types in both warp and weft, and functional yarn 150 would likely be much longer and contain many more LEDs 160. Thus, FIGS. 1 and 2, as well as other FIGURES herein, may be considered as illustrating a portion of a fabric or a portion of a functional yarn.

Suitable insulating yarn includes, for example, but are not limited to, yarn and/or thread and/or fiber of cotton, wool, silk, linen, flax, silk organza, synthetics, plastic, polyester, and the like, whether fiber, thread, monofilament, multi-stranded, spun, twisted or otherwise constructed, as may or may not be conventional.

Suitable electrically conductive yarn includes, for example, but is not limited to, copper, steel, stainless steel, nickel, silver, gold and/or other metal threads, whether single filament or plural stranded, twisted or braided or a wire or a flat strip, combinations of conductive metal and insulating threads and/or strands, electrically conductive plastics, and the like. One suitable electrically conductive yarn is Aracon.RTM. yarn which comprises one or more strands or threads of a metal-coated Kevlar.RTM. polymer and is commercially available from E. I. duPont de Nemoirs and Company of Wilmington, Del. Aracon.RTM. yarn can have an electrical conductivity approaching that of copper, e.g., about 10.sup.-3 Ohm/cm. Other suitable conductive yarn include metal-wrapped yarns and metal-plated yarn, and the like.

FIGS. 3A through 3D are plan view schematic diagrams of example embodiments of yarns 150a, 150b, 150c, including an example electronic circuit function suitable for a woven fabric as illustrated in FIGS. 1A and 1B.

FIG. 3A is a plan view schematic diagram of a yarn 150a including another example electronic circuit function, as for the woven fabric of FIGS. 1A and 1B. Functional yarn 150a includes plural electrical conductors 154, 155, 156 and an electronic device 160 on an insulating electrical or electronic substrate 152. In this specific example, electronic device 160 is a sensor, such as a temperature sensor. Substrate 152 is an elongate strip of insulating material, e.g., a polyimide or polyester or other material suitable for use as an electrical substrate.

Functional yarn 150a is viewed from the "back" as if substrate 152 is transparent so that conductors 154, 155, 156 on the front surface thereof, and sensors 160 attached thereto, are visible. Conductors 154 156 are formed on substrate 152 by any suitable means, such as by etching a conductive metal layer, e.g., copper layer, attached to substrate 152 using known methods for making electrical printed circuits and the like. As illustrated, each of conductors 154, 155 and 156 extend substantially the length of substrate 152 to provide three common connections to all of the sensors 160 thereon. Conductor 154 provides a common or ground connection, conductor 156 provides via contacts 166 a connection for electrical power for each sensor 160. Conductor 155 provides a conductor and contact 165 for applying an electrical signal for activating and/or reading sensor 160 and for receiving an electrical signal comprising data or information read from sensor 160.

Electrical connection between electrically conductive yarn 120 in the warp and conductors 154, 155, 156 of functional yarn 150a and/or electrically conductive yarn in the weft is satisfactorily made by the physical contact therebetween in a plain weave having a typical tightness and/or density of yarn, and may be supplemented, e.g., by a spot of electrically conductive adhesive at each connection 158. For proper electrical contact, functional yarn 150a is registered so that contacts 158g, 158d, 158p thereon each underlie a respective conductive yarn 120 where they cross. To this end, functional yarn 150a may include one or more registration marks or indicia 180 at one end thereof so that the loom may sense the position thereof in the weaving process to provide proper registration.

Optionally, conductors 154, 155 and/or 156 may be coated with an insulating coating, except at locations 158g, 158d, 158p to define contacts 158g, 158d, 158p where an electrical connection is to be made thereto. Also optionally, contacts 158g, 158d, 158p may have a spot of electrically conductive adhesive applied for making an electrical connection is to be made thereto., e.g., at intersections with conductive yarn 120. Sensors 160 may be connected to substrate 152 by any suitable means, e.g., by soldering or electrically conductive adhesive.

Electronic device 160 is preferably an addressable sensor which has a unique identification or address and which, when signaled by a data signal including such identification and/or address via its data terminal 165, performs a particular function. The function performed may be as simple as sensing a presently existing condition, such as temperature, or recording a given condition over a time period, whether for a given period or until again signaled, or may be more complex, such as providing processed data relating to a sensed condition. Each sensor 160 is powered by electrical power applied between ones of conducting yarn 120 connected to conductors 154 and 156 of functional yarn 150a and is activated by applying a suitable electrical addressing signal between common conductor 154 and data conductor 155, i.e. between two conducting yarn 120. One example of a suitable addressable sensor is type DS18B20X temperature sensor and/or thermostat flip-chip integrated circuit and the like available from Dallas Semiconductor--Maxim Integrated Products, Inc. located in Sunnyvale, Calif.

In a fabric 100, each conducting yarn 120 intersects functional yarn 150a to overlie one of the contacts 158 thereof. Thus, each sensor 160 has terminals that are connected via contacts 158g, 158d, 158p to a conductive yarn 120 that is accessible at an edge of fabric 100, so that all of sensors 160 on all of functional yarn 150a of fabric 100 are accessible from a single edge of fabric 100. In addition, where conductive yarn 120 are in the warp and functional yarn 150a are in the weft, fabric 100 may be woven to any desired length and be connected at one edge in the same format, e.g., at a single interface that may be standardized. Alternatively, fabric 100 may be cut into any desired length and each length may be connected via the standardized interface. Also alternatively, conductors 154, 155, 156 may be continuous over substantially the length of functional yarn 150a in which case only three conductive yarn 120 may be necessary to address addressable sensors 160, or conductors 154, 155, 156 may be discontinuous over the length of functional yarn 150a in which case more than three conductive yarn 120 may be necessary to address sensors 160.

Thus, sensors 160 of fabric 100 are in aggregate an addressable sensor matrix display having conductors 120 available at a single edge by which any one or more of sensors 160 may be addressed. It is noted that in an actual application, e.g., a textile or textile article, fabric 100 would likely be much larger and contain many more yarn of all types in both warp and weft, and functional yarn 150 would likely be much longer and contain many more sensors 160. Thus, FIGS. 1A and 1B, as well as other FIGURES herein, may be considered as illustrating a portion of a fabric or a portion of a functional yarn.

Circuit carriers, connectors and/or batteries and/or other components needed to connect with and/or operate fabric 100 may be attached to or incorporated into fabric 100, e.g., in cavities 106 woven therein and/or at an edge or edges thereof and/or at another convenient location. Examples of such components include, for example, decoders and/or drivers for LEDs, and/or for one or more rows and/or columns of LEDs, however, such components are preferably disposed on functional yarn 150.

Alternatively and optionally, electronic devices 160 may be of the sort that derive their operating power from the data and/or signals on the data conductor 155. Alternatively, electronic devices 160 may be powered via power conductor 156 by superimposing the data and/or signals on the power signal. One example of a sensor device 160 suitable for such arrangement is the type DS18B20X temperature sensor available from Dallas Semiconductor--Maxim Integrated Products, Inc. Thus, a functional yarn 150a may be, for example, a two-conductor equivalent of the three-conductor functional yarn 150a of FIG. 3A. Other addressing arrangements, e.g., those requiring more than three conductors, such as the I.sup.2C scheme which requires a clock signal conductor, may also be employed.

FIG. 3B is an example embodiment of a functional yarn 150b which includes additional electronic devices 170 on functional yarn 150, as may be employed to provide a woven non-matrix display having individually addressable pixels (LEDs) 160. Extending substantially the length of substrate 152 is conductor 154 connecting to all of the devices 160 at terminal 164 thereof and to electronic devices 170 at terminal 174 thereof, e.g., for providing a ground connection. Extending substantially the length of substrate 152 is conductor 158 connecting to all of electronic devices 170 at terminal 178 thereof, e.g., for providing a power connection. Also extending substantially the length of substrate 152 is conductor 155 connecting to all of electronic devices 170 at terminal 175 thereof, e.g., for providing a data signal thereto for addressing electronic devices 170 for selectively applying electrical power from conductor 158 to terminal 168 of LED 160 via output terminal 176 and conductor 156. As above, functional yarn 150b may include one or more registration indicia 180.

Electrical power is thus applied to all of electronic devices 170 via power conductor 158 and is selectively applied to ones of electronic devices 160 via the ones of electronic devices 170 that are addressed by the addressing signals, e.g., serial addressing signals, provided via data conductor 155. Electronic device 170 is preferably an addressable switch which has a unique identification or address and which, when signaled by a data signal including such identification and/or address via its data terminal 175, performs a particular function. The function performed may be as simple as making or breaking a connection between two of its terminals 176 and 178, whether for a given period or until again signaled, or may be more complex, such as providing a width-modulated or time modulated or a frequency signal at or between one or more of its terminals.

In a functional yarn 150b for a simple non-scanned, non-matrix array of light-emitting pixels, the state of each pixel may be set by addressing the appropriate switch and setting its state, e.g., either "on" or "off," to set the state of the pixel to either "on" or "off." One example of a suitable addressable switch is type DS2406 available from Dallas Semiconductor--Maxim Integrated Products, Inc. located in Sunnyvale, Calif. Alternatively, addressable switch 170 has plural controllable outputs for controlling plural electronic devices 160. In one embodiment, addressable switch 170 has seven outputs, as would be convenient for addressing a seven-segment LED display for displaying the numbers 0 9.

Such functional yarn 150b and a woven fabric display including same, employs serial addressing and is suitable for displaying still images and/or text or character messages. A fabric display may also be utilized for displaying moving images, e.g., video-rate displays, if sufficient addressing bandwidth or parallel addressing is available. Because an LED is emissive, it can produce a display that is not only easily seen in the dark, but may also be seen in daylight.

FIGS. 3C and 3D are an example embodiment of a functional yarn 150c which includes power and ground conductors 154, 156, various resistors R, and electronic devices 160 on functional yarn substrate 152, as may be employed to provide a woven non-matrix display having a pattern of electronic devices 160, e.g., LEDs 160, thereon. In particular, functional yarn 150c has a yarn substrate 152 that may be utilized with various different ones of devices 160 and resistors R attached thereto, e.g., in various serial and/or parallel circuits, as may be advantageous for making a unique and/or a specialized functional yarn. A portion of yarn substrate 152 is shown in FIG. 3D without electronic devices 160 and resistors R mounted thereon.

Spaced apart at a pitch 2P along the opposing edges of substrate 152 are conductor patterns 158 and 159 having respective contacts 158a, 158d and 159a and 159d to which electronic devices 160 and resistors R may be connected. Spaced apart at a pitch P along the opposing edges of substrate 152 are pairs of contacts 158a, 159a of patterns 158, 159 to which electronic devices 160 may be attached. Alternating adjacent pairs of contacts 158a are connected to each other by a conductor 158b which includes a contact 158d extending away from the edge of substrate 152, and alternating adjacent pairs of contacts 159a are connected to each other by a conductor 159b which includes contact 159d extending away from the edge of substrate 152. Conductors 158b, 159b are typically disposed alternatingly with respect to the pairs of contacts 158a and 159a so that plural devices 160 may be connected in series, if desired, and so that contacts 158d and 159d alternate at a pitch 2P.

Extending substantially the length of substrate 152 of functional yarn 150c in a central region thereof is conductor 154 providing a plurality of contacts 154d at which a connection, e.g., to ground, may be made via conductor 154. Also extending substantially the length of substrate 152 in the central region thereof is conductor 156 providing a plurality of contacts 156d at which a connection, e.g., to a source of power, may be made via conductor 156. Contacts 154d and contacts 156d are typically spaced apart at a pitch 2P and are disposed so as to be proximate respective ones of contacts 158d and 159d so that electronic devices 170, such as resistors R, may be mounted therebetween. Near one or both ends of functional yarn 150c are contacts 154c and 156c for respectively connecting conductors 154 and 156 to external circuits, such as to sources of power and ground potential. Conductors 154, 156, 158, 159 and the contacts thereof are typically an etched copper pattern on an insulating substrate 152, and may be covered by an insulating coating other than at the various contacts thereof.

In the example embodiment illustrated in FIG. 3C, the five electronic devices 160 (e.g., LEDs) at the left of the FIGURE are connected in series via ones of conductor patterns 158, 159 and the series connected devices 160 are connected to conductors 154 and 156 via two resistors R which are of ohmic value selected for a desired value of current flow through devices 160 with a specified value of potential applied between conductors 154, 156. Because there are two resistors R in series with the series connected devices 160, the necessary resistance value may be divided between the two resistors R in any desired proportion. Typically, one resistor R is of low ohmic value (e.g., 1 ohm) to serve as a jumper between one pair of connections 154d, 158d or 156d, 159d, and the other resistor R is a higher ohmic value (e.g., 100 ohms) connected between another pair of connections 154d, 158d or 156d, 159d, to determine the level of current flow through devices 160.

In an example embodiment of a functional yarn 150c, substrate 152 has a length of about 40 cm and a width of about 4 mm and is of a polyimide material. Series connections of between one and five LEDs 160 are provided, with contacts 158a, 159a each being about 1 mm by 2 mm in area and repeating at a pitch of about 9.5 mm. Contacts 154d, 156d, 158d and 159d are each about 0.5 mm by 0.5 mm, and are separated by a gap of about 0.6 mm. LEDs 160 operate at a current of about 20 milliamperes with about 12 volts is applied between conductors 154 and 156. For five LEDs 160 connected in series, a 1-ohm resistor R and a 100-ohm resistor R are utilized, whereas for a lesser number of LEDs 160 in series a higher value resistor R is utilized. Where two series circuits of LEDs 160 draw current through the same resistor R, the value of that resistor R is reduced proportionately