US 10,519,575 B2Granted

Conductive fabric, method of manufacturing a conductive fabric and apparatus therefor

AssigneeIntelligent Textiles Limited

InventorsAsha Peta Thompson, Stanley Shigezo Swallow

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Abstract

A woven fabric formed of a first set of yarns extending in a first direction, woven together with a second set of yarns extending in a second direction. The first set includes first conductors, while the second set includes second conductors. The first and second conductors cross over one another at crossing points. At each crossing point, a non-conductive element is disposed directly between the first and second conductors so as to provide a physical barrier between the first and second conductors. At some crossing points, a physical electrical connection is provided between crossing conductors in order to provide a permanent connection between the conductors. Non-conductive tie yarns are provided to fix the conductors in position. The structure provides a robust yarn with minimized risk of short circuiting between crossing conductors which are intended to be kept separate.

Claims31

Dependent claims

A woven fabric including:

A. a first set of yarns extending in a first direction, the first set of yarns including:
I. a first electrical conductor, and
II. a non-conductive element defined by non-conductive yarns,
B. a second set of yarns extending in a second direction, the second set of yarns including a second electrical conductor,
wherein:
a. the first and second sets of yarns are woven together,
b. the first and second electrical conductors cross over one another at a crossing point,
c. the non-conductive element is interposed directly between the first and second electrical conductors at the crossing point to provide a physical barrier between the first and second electrical conductors;
and
d. the non-conductive yarns of the non-conductive element:
(1) extend on opposing sides of the first conductor, and
(2) are:
i. situated over the first conductor, and
ii. laterally pressed, biased, or moved towards one another, at the crossing point, whereby a volume of non-conductive material is arranged over the first conductor at the crossing point so as to be interposed between the first and second conductors at the crossing point.

11 more elements

A method of making a conductive woven fabric including the steps of:

a. providing for one of the warp and the weft a first set of yarns including:
(1) a first electrical conductor, and
(2) a non-conductive element having non-conductive yarns,
b. providing for the other of the warp and the weft a second set of yarns including a second electrical conductor;
c. weaving the first and second sets of yarns and conductors such that the first and second electrical conductors cross over one another at a crossing point;
d. weaving the non-conductive element so as to be interposed directly between the first and second electrical conductors at the crossing point to provide a physical barrier between the first and second electrical conductors;
e. disposing the non-conductive yarns on opposing sides of the first conductor;
and
f. laterally arranging the non-conductive yarns over the first conductor at the crossing point by:
(1) pulling the non-conductive yarns over the first conductor, and
(2) laterally pressing, biasing, or moving the non-conductive yarns towards one another,
at the crossing point, so as to create a volume of non-conductive material interposed between the first and second conductors at the crossing point.

9 more elements

Dependencies are inferred from the claim text.