Flexible device module for fabric layer assembly and method for production

A fabric layer assembly comprising:

• a textile fabric with a first and a second embedded electrically conductive thread;
• a flexible foil comprising:
• a first conductive area;
• a second conductive area;
• and
• a non-conductive area,
• wherein the first conductive area is separated from the second conductive area by the non-conductive area therein between,
• wherein the first conductive area and the second conductive area each form electrodes of an electrical circuit therein between, and
• wherein the first conductive area and the second conductive area are configured to enable respective electrical connections with the first and the second embedded electrically conductive thread of the textile fabric;
• and
• a thermoplastic layer at least partially covering the flexible foil,
• wherein the flexible foil is mechanically bonded to the textile fabric via the thermoplastic layer,
• wherein the flexible foil has a flat shape with an outer circumference comprising inward notches configured as anchor points for respective ones of the first and the second embedded electrically conductive thread for holding and guiding the respective ones of the first and the second embedded electrically conductive thread over and in contact with respective ones of the first conductive area and the second conductive area for providing the respective electrical connections while the mechanical connection by the thermoplastic layer with the textile fabric is established,
• wherein the first embedded electrically conductive thread ends at the first notch and wherein the first embedded electrically conductive thread is positioned over and in electrical contact with the first conductive area, and
• wherein the second embedded electrically conductive thread ends at the second notch, wherein the second embedded electrically conductive thread is positioned over and in electrical contact with the second conductive area.

A method for connecting a flexible device module to a textile fabric with conductive threads, the method comprising

• providing a device module comprising:
• a flexible foil comprising:
• a first conductive area;
• a second conductive area;
• and
• a non-conductive area,
• wherein the first conductive area is separated from the second conductive area by the non-conductive area therein between,
• wherein the first conductive area and the second conductive area each form electrodes of an electrical circuit therein between, and
• wherein the first conductive area and the second conductive area are configured to enable respective electrical connections with the electrically conductive threads;
• and
• a thermoplastic layer at least partially covering the flexible foil, wherein the thermoplastic layer is configured to enable a mechanical connection between the flexible foil and the textile fabric,
• wherein the device module has a flat shape with an outer circumference comprising inward notches configured as anchor points for respective ones of the electrically conductive threads for holding and guiding the ones of the electrically conductive threads over and in contact with respective ones of the first conductive area and the second conductive area for providing the respective electrical connections while the mechanical connection by the thermoplastic layer with the textile fabric is established;
• bringing a first conductive thread through the first notch and bringing a second conductive thread through the second notch;
• positioning the device module onto the textile fabric with a middle part of each one of the first and the second conductive thread therein between while pulling respective ends of the conductive threads tight against the notches thereby guiding the each of the first and the second conductive thread over and in contact with a respective one of the first and the second conductive area;
• applying pressure and/or heat to the device module and the textile fabric to establish a mechanical bonding between the device module and the textile fabric via the thermoplastic layer while enabling respective electrical contacts between ones of the first and the second conductive thread and respective ones of the first and the second conductive areas.