Smart yarn and method for manufacturing a yarn containing an electronic device
Inventors
Fu, Jie • Ma, Ran • Scholten, Henk Jan
Assignees
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Publication Number
US-10480104-B2
Publication Date
2019-11-19
Expiration Date
Abstract
Once variation of a method for producing a smart yarn includes: advancing a set of wires into an assembly field; at each sensor site in a series of sensor sites along the set of wires, depositing solder paste onto the set of wires at the sensor site, placing a sensor into the solder paste on the set of wires at the sensor site, and heating the set of wires within the assembly field to reflow the solder paste; wrapping fibers around the set of wires and sensors arranged along the set of wires to form a continuous length of the smart yarn; separating a first segment of the smart yarn from the continuous length of the smart yarn; and weaving the first segment of the smart yarn into a garment.
Core Innovation
A smart yarn production method forms a continuous length of smart yarn by advancing a set of wires into an assembly field along a longitudinal direction, with a first wire parallel and laterally offset from a second wire by a wire offset distance approximating a terminal offset distance. A series of sensor sites is longitudinally offset along the set of wires as the wires sequentially enter the assembly field, and at each sensor site solder paste is deposited onto terminal locations on each wire while a sensor is placed so a first terminal contacts the first solder paste volume and a second terminal contacts the second solder paste volume while being offset relative to the first terminal.
The method reflows the solder paste by heating the set of wires within the assembly field so the solder paste volumes at the sensor terminals reflow while the sensor remains arranged along the set of wires. After soldering and wrapping preparation, fibers are wrapped around the set of wires and sensors arranged along the set of wires to form the continuous length of smart yarn, coupling terminal offset relationships between the laterally offset wires and the corresponding sensor terminals at sequential sensor sites.
In garment integration, the continuous smart yarn is separated into a first segment and woven into a garment. Sensor-containing segments are interweaved into a sock so the sensor locations are in the sole of the sock while ends terminate near a controller junction, and a second yarn is knitted into the sock excluding wires and sensors.
Claims Coverage
The partial content includes two independent method claims directed to producing a smart yarn and extending the smart yarn into a garment. Across the independent claims, the coverage centers on sequential sensor-site assembly using laterally offset parallel wires with terminal-offset sensors, solder paste deposition and reflow, fiber wrapping, and garment weaving.
Continuous smart yarn from laterally offset wires with terminal-offset sensors
Advancing a set of wires into an assembly field with a first wire parallel and laterally offset from a second wire by a wire offset distance approximating a terminal offset distance; depositing first and second solder paste volumes onto first and second terminal locations at each sensor site; placing a sensor so first and second terminals contact the corresponding solder paste volumes while the second terminal is offset from the first by the terminal offset distance; heating the wires within the assembly field to reflow the solder paste volumes; and wrapping fibers around the set of wires and sensors to form a continuous length of smart yarn.
Separating the smart yarn into a segment for garment weaving
Advancing a set of wires into an assembly field with a first wire parallel and laterally offset from a second wire by a wire offset distance approximating a terminal offset distance; depositing first and second solder paste volumes onto first and second terminal locations at each sensor site; placing a sensor so first and second terminals contact the corresponding solder paste volumes while the second terminal is offset from the first by the terminal offset distance; heating the wires within the assembly field to reflow the solder paste volumes; wrapping fibers around the set of wires and sensors to form a continuous length of smart yarn; separating a first segment of the smart yarn from the continuous length; and weaving the first segment of the smart yarn into a garment.
Both independent claims cover smart-yarn formation based on laterally offset parallel wires, sensor sites introduced sequentially into an assembly field, solder paste deposition at terminal locations with terminal-offset sensor placement, heating for reflow, and fiber wrapping. One independent claim limits the result to a continuous smart yarn, while the other further requires separating a segment and weaving it into a garment.
Stated Advantages
Documented Applications
Weaving a first segment of the smart yarn into a garment.
Interweaving sensor-containing smart-yarn segments into a sock such that sensor locations are in the sole of the sock and ends terminate near a controller junction.
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