# US 2021/0277544 A1 · Machine-knittable conductive hybrid yarns

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- Number: US 2021/0277544 A1
- Document ID: US20210277544A1
- Status: Published application
- Kind: A1
- Application number: 16/845,796
- Filed: 2020-04-10
- Published: 2021-09-09
- Earliest claimed: 2019-04-10
- Assignees: Propel, LLC
- Applicants: Propel, LLC
- Inventors: Clare King; Anjali Khemani; Birgit Leitner
- Web page: https://patentgrep.com/patent/US20210277544A1

## CPC

- D02G 3/36: Cored or coated yarns or threads ({D02G3/34, D02G3/40 take precedence}; elastic yarns or threads D02G3/32)
- A61B 5/256: Wearable electrodes, e.g. having straps or bands
- A61B 5/265: containing silver or silver chloride
- A61B 5/266: containing electrolytes, conductive gels or pastes
- A61B 5/27: Conductive fabrics or textiles
- A61B 5/282: Holders for multiple electrodes (for introduction into the body A61B5/287)
- D02G 3/045: {all components being made from artificial or synthetic material}
- D02G 3/047: {including aramid fibres}
- D02G 3/12: Threads containing metallic filaments or strips
- D02G 3/441: {Yarns or threads with antistatic, conductive or radiation-shielding properties (electroconductive, anti-static or radiation-shielding filaments D01F1/09, D01F1/106; anti-static fabrics D03D15/533; conducting, insulating or anti-static layers for floor coverings D06N7/0042)}
- D02G 3/443: {Heat-resistant, fireproof or flame-retardant yarns or threads (fire- or flame-proof filaments D01F1/07; woven fabrics using heat-resistant or fireproof threads D03D15/513)}
- D04B 1/24: wearing apparel
- A61B 5/28: for electrocardiography [ECG]
- A61B 5/291: for electroencephalography [EEG]
- A61B 5/296: for electromyography [EMG]
- A61B 5/6804: {Garments; Clothes}
- A61B 2562/125: characterised by the manufacture of electrodes
- A61B 2562/14: Coupling media or elements to improve sensor contact with skin or tissue
- A61B 2562/18: Shielding or protection of sensors from environmental influences, e.g. protection from mechanical damage
- D03D 1/0088: {Fabrics having an electronic function}
- D04B 1/12: characterised by thread material
- D04B 1/126: {with colour pattern, e.g. intarsia fabrics}
- D10B 2211/02: Wool
- D10B 2401/16: antistatic; conductive
- D10B 2403/02431: with electronic components, e.g. sensors or switches
- D10B 2501/00: Wearing apparel
- H05K 1/038: {Textiles (used as reinforcing materials for organic insulating substrates H05K1/0366)}
- H05K 2201/0281: Conductive fibers
- H05K 2201/10151: Sensor
- D02G: CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D)
- D04B: KNITTING
- D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS

## Abstract

A machine knittable hybrid yarn for providing conductive traces through a textile is disclosed. The hybrid yarn includes conductive wires coated with an insulating material and twisted together with a nonconductive yarn. The nonconductive yarn is from a strong, inelastic, and nonconductive fiber, such as a meta-aramid or para-aramid that protects the integrity of the conductive wire during knitting. The conductive wire can be copper-clad stainless steel or copper wire is coated with polyurethane, and the nonconductive yarn can have no-drip and no-drip properties to allow ablation of the hybrid yarn to remove the conductive yarn and insulating coating on the wire such that the ablated region becomes externally conductive and suitable for making an electrical contact. The hybrid yarn can be bonded with nylon or similar polymer after twisting.

## Claims

### Claim 1

A machine-knittable hybrid yarn, comprising:
a non-conductive yarn; and
a conductive wire twisted with the nonconductive yarn, the conductive wire having an exterior layer of an insulating material.

### Claim 2 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn is twisted together with the conductive wire.

### Claim 3 (depends on 2)

The hybrid yarn of claim 2,
wherein non-conductive yarn and the conductive wire are twisted together with Z twist or an S twist from the single twisting process.

### Claim 4 (depends on 1)

The hybrid yarn of claim 1,
wherein the conductive wire is twisted with the conductive yarn at between 1 and 15 twists per inch.

### Claim 5 (depends on 4)

The hybrid yarn of claim 4,
wherein the conductive wire is twisted with the conductive yarn at between 5 and 12 twists per inch.

### Claim 6 (depends on 1)

The hybrid yarn of claim 1,
wherein the conductive wire defines a continuous strand of metal along the hybrid yarn.

### Claim 7 (depends on 1)

The hybrid yarn of claim 1,
wherein the hybrid yarn is bonded with a polymer layer.

### Claim 8 (depends on 7)

The hybrid yarn of claim 7,
wherein the hybrid yarn is bonded with Nylon.

### Claim 9 (depends on 1)

The hybrid yarn of claim 1,
wherein the insulating layer comprises a polymer coating.

### Claim 10 (depends on 1)

The hybrid yarn of claim 1, wherein the nonconductive yarn is 1500 denier or finer.

### Claim 11 (depends on 1)

The hybrid yarn of claim 1, wherein the conductive wire is approximately 10 to 100 microns thick.

### Claim 12 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn has an elasticity less than that of the twisted conductive wire such that the conductive wire does not break before the non-conductive yarn under tensile loading of the hybrid yarn.

### Claim 13 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn is fire retardant and self-extinguishing.

### Claim 14 (depends on 10)

The hybrid yarn of claim 10,
wherein the non-conductive yarn is no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

### Claim 15 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn has a tensile strength higher than the conductive wire.

### Claim 16 (depends on 1)

The hybrid yarn of claim 1,
wherein the nonconductive yarn has a Young's modulus of at least 60 GPa.

### Claim 17 (depends on 1)

The hybrid yarn of claim 1,
wherein the nonconductive yarn has a break elongation percentage of 4.2 or less.

### Claim 18 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn comprises at least one of an aramid, meta-aramid, or para-aramid polyamide fiber.

### Claim 19 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn comprises at least one: Ultra High Molecular Weight Polyethene (UHMWPE), Polybenzimidazole (PBI), Polyphenylene Benzobisoxazole (PBO), High Strength Polyester, Liquid-Crystal Polymer (LCP), or spider silk.

### Claim 20 (depends on 1)

The hybrid yarn of claim 1,
wherein the conductive wire comprises a copper-clad stainless steel wire or a solid copper wire.

### Claim 21 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn and the insulating material each have a decomposition temperature less than a melting point of the conductive wire.

### Claim 22 (depends on 1)

The hybrid yarn of claim 1,
wherein the non-conductive yarn comprises staple fibers.

### Claim 23 (depends on 1)

The hybrid yarn of claim 1,
wherein the conductive wire is a first conductive wire, and
the hybrid yarn further comprises a second conductive wire twisted with the nonconductive yarn.

### Claim 24 (depends on 1)

The hybrid yarn of claim 1,
wherein non-conductive yarn comprises staple fibers.

### Claim 25

A machine-knittable hybrid yarn, comprising:
a non-conductive yarn; and
a conductive wire twisted together with the nonconductive yarn, the conductive wire having an exterior layer of an insulating material,
wherein the non-conductive yarn has a tensile strength higher than a tensile strength of the conductive wire, and
wherein the non-conductive yarn is fire retardant and self-extinguishing.

### Claim 26

A method of making a machine-knittable hybrid yarn, the method comprising:
twisting, in a single process, a non-conductive yarn with a conductive wire, the conductive wire having an exterior coated with an insulating material.

### Claim 27 (depends on 26)

The method of claim 26, further comprising:
bonding, after the twisting, the twisted non-conductive yarn and conductive wire with a nonconductive exterior layer.

### Claim 28 (depends on 27)

The method of claim 27,
wherein the nonconductive layer comprises a polymer.

### Claim 29 (depends on 26)

The method of claim 26,
wherein the conductive wire is twisted with the conductive yarn at between 1 and 15 twists per inch.

### Claim 30 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn has an elasticity less than that of the twisted conductive wire such that the conductive wire does not break before the non-conductive yarn under tensile loading of the hybrid yarn.

### Claim 31 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn is fire retardant and self-extinguishing.

### Claim 32 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn has a tensile strength higher than the conductive wire.

### Claim 33 (depends on 26)

The method of claim 26,
wherein the nonconductive yarn has a Young's modulus of at least 60 GPa.

### Claim 34 (depends on 26)

The method of claim 26,
wherein the nonconductive yarn has a break elongation percentage of 4.2 or less.

### Claim 35 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn comprises at least one of: an aramid, meta-aramid, or para-aramid polyamide fiber.

### Claim 36 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn comprises at least one: Ultra High Molecular Weight Polyethene (UHMWPE), Polybenzimidazole (PBI), Polyphenylene Benzobisoxazole (PBO), High Strength Polyester, Liquid-Crystal Polymer (LCP), or spider silk

### Claim 37 (depends on 26)

The method of claim 26,
wherein the conductive wire comprises a copper-clad stainless steel wire or a solid copper wire.

### Claim 38 (depends on 26)

The method of claim 26,
wherein the non-conductive yarn comprises staple fibers.