A textile-based electrode system includes a first fabric layer having an inner and an outer surface. The inner surface includes a knitted electrode configured to be placed in contact with the skin of a user. A second fabric layer is disposed and configured to contact the outer surface of the first fabric layer. The second fabric layer includes a knitted conductive pathway configured to be electrically coupled to the knitted electrode. Furthermore, a third fabric layer is configured and disposed to contact the second fabric layer. A connector is disposed on the third fabric layer and is configured to be electrically coupled to the knitted conductive pathway. The second fabric layer can be folded about a first fold axis and the third fabric layer can be folded about a second fold axis to place the second fabric layer in contact with the first fabric layer and the third fabric layer.

An electronic garment includes an elastic textile garment configured to be worn on anatomy of an associated wearer. The elastic textile garment has an inner surface arranged to contact the anatomy when the elastic textile garment is worn on the anatomy. Electrodes are secured to the inner surface of the elastic textile garment. Each electrode includes at least an exposed portion of an insulated electrically conductive thread that is sewn onto or into the elastic textile garment. An electrically conductive polymer electrode material, such as a mixed ionic-electronic conducting (MIEC) material, is arranged to contact the electrodes, for example as an inner compression sleeve liner coated or infused with the MIEC material. The elastic textile garment and the electrically conductive threads may be formed together by three-dimensional (3D) knitting. A scent may be added to the elastic textile garment.

Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.

Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.

A textile device for detecting liquids comprising a matrix fabric obtained by knitting, a first non-insulated conductive wire and a second non-insulated conductive wire knitted with the matrix fabric, a source of electric energy connected to the non-insulated conductive wires in order to create a first electric circuit and to have a potential difference between the non-insulated conductive wires, an electrical resistance measuring device configured to measure the electric resistance R in the first electric circuit. The textile device is configured in such a way that, when the non-insulated conductive wires electrically connect by means of a liquid, the electrical resistance measuring system measures a variation of electric resistance R in said first electric circuit. Furthermore, at least one insulated conductive wire is provided connected to a source of electric energy in order to create a second electric circuit.

A system for continuously humidifying a textile electrode during its use by a human is disclosed. The electrode can be part of a garment or textile where the textile electrode is positioned against the skin. A reservoir positioned against the electrode and opposite the user's skin can be made from a material with hydrophilic and hydrophobic properties, such as natural wool or a skincore material. The reservoir receives and retains moisture from the user's skin through the electrode, as well as from a pre-wetting of the exposed user-facing side of the electrode. A seal can surround the reservoir and the electrode, with the seal extending beyond electrode. The seal can be a patch with heat activated adhesive at the edge to flow the textile to form a moisture barrier around the electrode. An electrical contact on the electrode can connect conductive wires from outside the seal to the electrode.

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.

A system of fibre based temperature sensor integrated into abase fabric layer for a garment, the system comprising: a set of wall fibres interlaced with one another to form a first wall structure defining a first cavity along a length and a second wall structure defining a second cavity along the length, the set of wall fibres comprising nonconductive material; at least one conductive fibre miming along the length within each cavity, such that the set of wall fibres of the wall structures encloses each at least one conductive fibre in order to electrically insulate each at least one conductive fibre from an environment along the length external to the cavities; and a set of base fibres interlaced with one another to form the base fabric layer.

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.

Provided is a wearable device and a method of manufacturing the same. The wearable device includes: a wearable flexible printed circuit board having a circuit pattern formed on a base substrate having flexibility, air-permeability, and waterproofness; and a functional module mounted on the wearable flexible printed circuit board.