Smart yarn and method for manufacturing a yarn containing an electronic device
Inventors
Fu, Jie • Ma, Ran • Scholten, Henk Jan
Assignees
Interested in licensing this patent?
MTEC can help explore whether this patent might be available for licensing for your application.
Publication Number
US-11891730-B2
Publication Date
2024-02-06
Expiration Date
Abstract
One variation of a method for producing a smart yarn includes: aligning a set of sensing elements offset along a lateral axis in a magazine, wherein each sensing element in the set of sensing elements includes a sensor, a first conductive lead extending from a first side of the sensor along a longitudinal axis perpendicular to the lateral axis, and a second conductive lead extending from a second side of the sensor opposite the first side and along the longitudinal axis; wrapping a set of fibers into a yarn within a wrapping field; feeding a leading end of a first sensing element, in the set of sensing elements, from the magazine into the wrapping field; releasing the first sensing element from the magazine into the wrapping field; encasing the first sensing element between the set of fibers within the yarn; and repeating this process for the set of sensing elements.
Core Innovation
A smart yarn is produced by aligning a set of sensing elements offset along a lateral axis in a magazine or dispenser, where each sensing element includes a sensor and conductive leads extending from opposite sides of the sensor. A leading end of a first sensing element is fed into a wrapping field or wrapping site, released, and encased between a set of fibers within the yarn, and a second sensing element is then fed and released in response to a trailing end passing through the wrapping field.
The encasing of the second sensing element is performed so that its position is longitudinally offset behind the first sensing element within the yarn, continuing yarn formation as successive sensing elements are released and encased. The method emphasizes serial placement of sensing elements into a yarn by repeated feeding, releasing, and encasing at a wrapping field or wrapping site while maintaining longitudinal offset placement between consecutive sensing elements.
The disclosure also includes forming sensing elements through a flexible serpentine circuit board workflow, including a serpentine trace with component sites on a flexible substrate, installing sensors at the component sites, applying sealant, separating the serpentine trace to form a flexible serpentine circuit board, and loading into a magazine for feeding into the wrapping field. Downstream integration is described by knitting the resulting yarn into garments, including a sock, with conductive leads trimmed along the conductive leads of temperature sensors and electrically coupled to a controller near an opening of the sock.
Claims Coverage
The partial content contains two independent claims, each covering a method for producing or using smart yarn by serially wrapping fibers around laterally offset sensing elements and forming a yarn with longitudinally offset sensing elements. Across the independent claims, the key inventive features are the offset sensing-element storage/feeding arrangement, the wrapping-field encasing of sequential sensing elements, and the longitudinal offset relationship maintained between consecutive sensing elements within the yarn.
Lateral-axis offset sensing elements in a magazine with serial feeding into a wrapping field
Aligning a set of sensing elements offset along a lateral axis in a magazine or dispenser, feeding a leading end of a first sensing element from the magazine or dispenser into the wrapping field or wrapping site and releasing it, then feeding and releasing a second sensing element in response to a trailing end passing through the wrapping field or wrapping site.
Encasing sequential sensing elements within wrapped fibers while maintaining longitudinal offset
Wrapping a set of fibers into a yarn within a wrapping field or wrapping site, encasing the first sensing element between the set of fibers within the yarn, and encasing the second sensing element between the set of fibers and longitudinally offset behind the first sensing element within the yarn.
Storing offset sensing elements in a dispenser and wrapping fibers at a wrapping site
Storing, in a dispenser, a set of sensing elements offset along a lateral axis, feeding a leading end of a first sensing element from the dispenser toward a wrapping site, and at the wrapping site wrapping a set of fibers around the first sensing element to form a yarn.
Continuing the yarn by wrapping a second sensing element longitudinally offset behind the first
In response to a trailing end of the first sensing element passing the wrapping site, feeding a leading end of a second sensing element from the dispenser toward the wrapping site, and at the wrapping site wrapping the set of fibers around the second sensing element to continue the yarn, where the leading end of the second sensing element is longitudinally offset behind the trailing end of the first within the yarn.
Across the two independent claims, the inventive coverage centers on serial yarn manufacture by feeding laterally offset sensing elements into a wrapping field or wrapping site, encasing them between wrapped fibers, and maintaining a longitudinally offset relationship between consecutive sensing elements within the resulting yarn.
Stated Advantages
Discrete/obscured component feel via smart yarn architecture with discreet smart-spot indication.
Visual location/verification using light elements.
Reduced breakage via tension control and protective packing fibers.
Compatibility with existing PCB/SMT and textile manufacturing infrastructure.
Documented Applications
Integrating the smart yarn into garments by knitting or weaving, including a sock with temperature sensors placed at offset target locations and conductive leads electrically coupled to a controller near a sock opening.
Interested in licensing this patent?