Abstract
The present invention relates to an elongated elastic seam tape comprising an elongated elastic conductor as well as to a method of manufacturing such an elongated elastic seam tape.
Claims
1. An elongated elastic seam tape, comprising: an elongated elastic first layer; an elongated elastic second layer, partially bonded to the first layer; and an elongated elastic conductor; wherein each longitudinal edge of the second layer is bonded to a corresponding longitudinal edge of the first layer so as to form a lumen extending along the entire seam tape between the first and second layers; and wherein the conductor is movably positioned within said lumen.
2. The elongated seam tape of claim 1, wherein the conductor remains electrically conductive at a strain of at least 50%.
3. The elongated seam tape of claim 1, wherein the lumen has a first cross-sectional area and wherein the conductor has a second cross-sectional area and wherein the ratio between the first and second cross-sectional areas is at least 1.4.
4. The elongated seam tape of claim 1, wherein the second layer comprises an elastic polymer, and wherein the first layer comprises one or a combination of the following materials: elastic textile, elastic polymer, or thermoplastic elastic polymer.
5. The elongated seam tape of claim 4, wherein the melting point of a material of the first layer is higher than that of a material of the second layer.
6. The elongated seam tape of claim 1, wherein the conductor is pre-stretched within said lumen.
7. The elongated seam tape of claim 1, wherein the second layer is configured to be peeled off of the first layer at least at one longitudinal end of the seam tape so as to expose a section of the conductor.
8. The elongated seam tape of claim 1, wherein each longitudinal edge of the second layer is bonded to a corresponding longitudinal edge of the first layer and one or more intermediate longitudinal sections of the second layer are bonded to one or more corresponding intermediate longitudinal sections of the first layer so as to form two or more lumina extending along the entire seam tape between the first and second layers, and wherein an elongated elastic conductor is movably positioned within each of said lumina.
9. The elongated seam tape of claim 1, further comprising: an elongated elastic third layer; an elongated elastic fourth layer, partially bonded to the third layer; and a second elastic elongated conductor; wherein each longitudinal edge of the fourth layer is bonded to a corresponding longitudinal edge of the third layer so as to form a second lumen extending along the entire seam tape between the third and fourth layers; wherein the second conductor is movably positioned within said second lumen; and wherein the third layer is different from the second layer or wherein the third layer is integral with the second layer.
10. The elongated seam tape of claim 1, further comprising an electrical connector connected to one end of the conductor.
11. The elongated seam tape of claim 10, wherein the connector comprises a crimp sleeve attached to the end of the conductor and a connector element longitudinally protruding from the lumen of the seam tape.
12. The elongated seam tape of claim 11, wherein the conductor in its unstretched equilibrium state has a first length and wherein the lumen in the unstretched equilibrium state of the seam tape has a second length greater than the first length.
13. The elongated seam tape of claim 27, wherein the first and second layers comprise an adhesive and wherein the lumen is sealed by the connector element and the adhesive layers surrounding the connector element.
14. The elongated seam tape of claim 11, wherein the connector element comprises a metal ring and a conductive rivet-type snap button connector, wherein the rivet-type snap button connector comprises a rivet stud, and wherein the rivet stud extends through the opening of the metal ring of the connector element.
15. A fabric comprising the elongated seam tape of claim 10 bonded thereto.
16. The fabric of claim 15, wherein the crimp sleeve of the connector is adhesively bonded to the first and/or second layer of the seam tape and/or to the fabric.
17. The fabric of claim 15, wherein a reinforcement layer is adhesively bonded to the fabric.
18. The fabric of claim 17, wherein the reinforcement layer is adhesively bonded to a part of the seam tape different from the connector and/or wherein the reinforcement layer is adhesively bonded to the connector of the seam tape.
19. A method of manufacturing an elongated elastic seam tape, the method comprising the following steps: providing first and second elongated elastic layers and an elongated elastic conductor positioned between the first and second layers; bonding each longitudinal edge of the second layer to a corresponding longitudinal edge of the first layer such that a lumen extending along the entire seam tape between the first and second layers is formed and such that the conductor extends along said lumen.
20. The method according to claim 19, wherein the conductor is provided in a pre-stretched configuration and wherein the pre-stretched conductor extends along the entire length of the lumen while the first and second layers are in their unstretched equilibrium state.
21. The elongated seam tape of claim 2, wherein the conductor remains electrically conductive at a strain of at least 75%.
22. The elongated seam tape of claim 2, wherein the conductor remains electrically conductive at a strain of at least 100%.
23. The elongated seam tape of claim 3, wherein the ratio between the first and second cross-sectional areas is at least 2.
24. The elongated seam tape of claim 3, wherein the ratio between the first and second cross-sectional areas is at least 5.
25. The elongated seam tape of claim 4, wherein the elastic polymer is a thermoplastic elastic polymer.
26. The elongated seam tape of claim 7, wherein the second layer is configured to be manually peeled off of the first layer.
27. The elongate seam tape of claim 11, wherein the crimp sleeve in the unstretched equilibrium state of the seam tape is completely withdrawn into the lumen of the seam tape.
28. The fabric of claim 22, wherein the second layer of the seam tape is adhesively bonded to the fabric.
29. The fabric of claim 25, wherein, in at least one cross section through the fabric (20), fabric material is positioned under the crimp sleeve of the connector and reinforcement layer material is positioned above the crimp sleeve.
30. The fabric of claim 25, wherein the reinforcement layer is a textile reinforcement layer.
Description
[0066] Preferred embodiments of the present invention are further elucidated below with reference to the figures, which show:
[0067] FIG. 1 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0068] FIG. 2 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0069] FIG. 3 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0070] FIG. 4 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0071] FIG. 5 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0072] FIG. 6 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0073] FIG. 7 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0074] FIG. 8 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0075] FIG. 9 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0076] FIG. 10 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0077] FIG. 11 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0078] FIG. 12 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0079] FIG. 13 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0080] FIG. 14 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0081] FIG. 15 a cross section through a preferred embodiment of a seam tape according to the present invention;
[0082] FIG. 16 a longitudinal section through a preferred embodiment of a seam tape according to the present invention being bonded to a fabric;
[0083] FIG. 17 a longitudinal section through a preferred embodiment of a seam tape according to the present invention being bonded to a fabric;
[0084] FIG. 18 a longitudinal section through a preferred embodiment of a seam tape according to the present invention being bonded to a fabric;
[0085] FIG. 19 a longitudinal section through a preferred embodiment of a seam tape according to the present invention being bonded to a fabric;
[0086] FIG. 20 a longitudinal section through a preferred embodiment of a seam tape with a connector according to the present invention; and
[0087] FIG. 21 a longitudinal section through a preferred embodiment of a seam tape with a connector according to the present invention.
[0088] FIG. 1 shows a cross section (perpendicular to the longitudinal extension of the seam tape) through a preferred embodiment of an elongated elastic seam tape 101 according to the present invention. The seam tape 101 comprises an elongated elastic first layer 1 consisting of, e.g., a textile tape or a plastic film, and an elongated elastic second layer 2 consisting of an adhesive material such as a thermoplastic elastic polymer (or thermoplastic elastomer). As schematically shown in FIG. 1, each longitudinal edge of the second layer 2 (corresponding to the left and right edges in the cross section shown) is bonded to a corresponding longitudinal edge of the first layer 1 so as to form a lumen 4 extending along the entire seam tape between the first and second layers. An electrical conductor 3 is movably positioned within said lumen 4.
[0089] The tape may generally have any dimensions suitable for its use. Typically, the width of the tape (corresponding to the left-right-extension in FIG. 1) is between 5 mm and 5 cm, preferably between 5 mm and 1 cm and more preferably between 6 mm and 11 mm. The thickness of the seam tape depends on the number of layers (see the subsequent embodiments) but is generally between 0.5 mm and 1 cm, preferably between 0.8 mm and 5 mm. In general, however, the thickness of the seam tape will vary along its width since the thickness at the position of the conductor will be greater than the thickness of the rest of the tape as schematically shown in FIG. 1. Typically, the thickness of the top layer is between 0.2 mm and 3 mm, the thickness of the insulation layers is between 0.02 mm and 2 mm and the thickness of the adhesive layers is between 0.02 mm and 2 mm. The length of the elongated elastic seam tape is preferably greater than 0.3 m, more preferably greater than 0.5 m, even more preferably greater than 2 m, and most preferably greater than 10 m. The elongated elastic seam tape of such a length may, e.g., be provided in the form of a roll. Before use, the user cuts off a segment of the elongated elastic seam tape in accordance with his needs.
[0090] Of course, the skilled person will understand that the shape and relative dimensions of the components of the seam tape as shown in FIG. 1 are merely schematic in nature and that, e.g., the cross section of the first layer 1 need not be rectangular and that the conductor need not be cylindrical. Moreover, the lumen 4 may have different shapes and sizes deviating from the schematic drawing shown in FIG. 1, which apparently will also have an influence on the shape and curvature of the second layer 2.
[0091] It is, however, preferred that the ratio between the cross-sectional area of the lumen and the cross-sectional area of the conductor is at least 1.4, preferably at least 2, more preferably at least 5. In the embodiment shown in FIG. 1, said ratio is greater than 5. The distance between the two points where the first and second layers start to be bonded to each other, measured perpendicular to the length extension defines a width w.sub.1 of the lumen, see FIG. 1. The ratio between said width w.sub.1 and the width w of the seam tape is preferably larger than 0.2, preferably larger than 0.4 and more preferably larger than 0.6.
[0092] As mentioned above, the seam tape 101 of the present invention may comprise one or more additional layers on either or both of the first and second layers. Some exemplary embodiments comprising such additional layers are shown in FIGS. 2 to 4. For example, a textile tape or a plastic film 6 may be bonded to the first layer 1 by means of an additional adhesive layer 5 as shown in FIG. 2. Alternatively, an additional protective or insulation layer 7 may be provided adjacent to the second layer 2 as shown in FIG. 3. Said protective or insulation layer 7 may comprise an elastic polymer such as a thermoplastic high-melting-temperature polyurethane having, e.g., a melting point above 170° C. Since the protective or insulation layer 7 does not necessarily comprise an adhesive material, an additional adhesive layer 8 may be foreseen for bonding or attaching the seam tape to a fabric as discussed further below.
[0093] Of course, the additional layers 5 and 6 shown in FIG. 2 as well as the additional layers 7 and 8 shown in FIG. 3 may be provided in one and the same embodiment as shown in FIG. 4.
[0094] As discussed above, two or more elongated elastic conductors may be provided within the inventive seam tape. For example, two or more conductors may be provided within one plane of the seam tape, i.e. between the same adjacent layers 1 and 2 as shown in the embodiments of FIGS. 5 to 8.
[0095] In the seam tape 101 according to the embodiment of FIG. 5, each longitudinal edge of the second layer 2 is bonded to a corresponding longitudinal edge of the first layer 1 (similar to the embodiment shown in FIG. 1) and one intermediate longitudinal section of the second layer is bonded to one corresponding intermediate longitudinal section of the first layer so as to form two lumina 41 and 42 extending along the entire seam tape between the first and second layers. In each of the lumina 41 and 42, an elongated elastic conductor 31, 32 is movably positioned. Of course, this concept may be extended to three or more lumina containing three or more conductors by providing further intermediate sections analogously to the embodiment shown in FIG. 5.
[0096] FIGS. 6 to 8 show preferred embodiments of a seam tape 101 having a layered structure corresponding to those of FIGS. 2 to 4, however, with the presence of two lumina containing two conductors analogously to the embodiment shown in FIG. 5.
[0097] Alternatively or in addition, another conductor may be provided in a different plane of the seam tape. For example, the seam tape 101 according to the embodiment shown in FIG. 10 comprises an elongated elastic third layer 11 and an elongated elastic fourth layer 12, partially bonded to the third layer 11, wherein each longitudinal edge of the fourth layer 12 is bonded to a corresponding longitudinal edge of the third layer 11 so as to form a second lumen 42 extending along the entire seam tape between the third and fourth layers. A second elastic elongated conductor 32 is movably positioned within said second lumen 42. In addition, the seam tape of FIG. 10 comprises another adhesive layer 5 and a textile tape or plastic film 6. In the embodiment shown in FIG. 10 (and similarly in the embodiments in FIGS. 11 and 12, respectively), the third layer 11 is different from the second layer 2. However, as shown in FIG. 9, the third layer 11 may also be integral with the second layer 2. While the third layer 11 in all embodiments shown in FIGS. 10 to 12 is immediately adjacent to the second layer 2, one or more additional intermediate layers may be provided between the second layer 2 and the third layer 11.
[0098] In all embodiments shown in FIGS. 1 to 12, the lumen 4 (or the lumina 41 and 42) is positioned such as to create a bulge in the second layer 2 (and/or the fourth layer 12). In other words, the surface of the first layer 1 being adjacent to the second layer 2 is substantially planar and appears not to be affected by the presence of the lumen 4, 41, 42, whereas the second layer is curved or bent so as to accommodate the lumen between the first and second layers.
[0099] It is, however, also an option that the lumen 4 (or the lumina 41 and 42) is somewhat symmetrically disposed between the first and second layers as shown, for example, in FIG. 13. In this case, both the first layer 1 and the second layer 2 are curved or bent along the width direction of the seam tape so as to accommodate the lumen 4, 41, 42 therebetween. Such a symmetrically positioned lumen 4 can, for example, be achieved if the material of both layers 1 and 2 comprises an adhesive such as a thermoplastic elastic polymer, which material is then deformed during bonding. While the adhesive material of the layers 1 and 2 need not be identical, a symmetrical arrangement of the lumen 4 between the layers 1 and 2 is most easily achieved if the adhesive materials of the first layer 1 and the second layer 2 have a comparable melting temperature.
[0100] By contrast, an asymmetrical positioning of the lumen 4 as shown, for example, in FIG. 1 may be most easily achieved if the melting temperature of the first layer is substantially higher than the melting temperature of the second layer. In this case, only the material of the second layer 2 is deformed during bonding, whereas the first layer 1 remains effectively unaffected by the temperature and pressure applied during bonding.
[0101] FIG. 14 shows a further preferred embodiment of the inventive seam tape 101 with a lumen 4 similar to that shown in FIG. 13. The first layer 1 and the second layer 2 also in this case comprise an adhesive material. On top of the first layer, a protective or insulation layer 9, another adhesive layer 5 and a top layer 6 are provided. Below the second layer 2, a further protective or insulation layer 7, a further adhesive layer 8 and removable film such as a release paper 10 are provided. The preferred embodiment of FIG. 14 provides an improved protection for the conductor, thanks to the protective insulation layers 9 and 7 which surround the conductor.
[0102] FIG. 15 shows a further preferred embodiment of the inventive seam tape 101 with two lumina 4 being present on different levels or planes of the laminate. A first lumen 41 is provided between adhesive first and second layers 1 and 2 and a second lumen 42 is provided between adhesive third and fourth layers 11 and 12. Between the second layer 2 and the third layer 11, a protective or insulation layer 13 is provided. Moreover, the seam tape 101 comprises a protective or insulation layer 9, an adhesive layer 5 and a textile tape or plastic film 6 on top of the first layer 1 and a protective or insulation layer 7 and an adhesive layer 8 below the fourth layer 12. Of course, a removable film (not shown) may be provided similar to the embodiment shown in FIG. 14. The preferred embodiment of FIG. 15 provides an improved protection for each of the conductors 31, 32, thanks to the protective insulation layers 9, 13 and 7 which surround the conductors. Furthermore, the preferred embodiment of FIG. 15 provides optimal insulation between the conductors, thanks to the protective insulation layer 13 separating the conductors.
[0103] FIGS. 16 to 19 show various embodiments of a fabric 20 comprising an elongated seam tape according to the present invention bonded thereto. While all embodiments shown in FIGS. 16 to 19 are based on a seam tape as shown in FIG. 13 comprising two adhesive layers 1 and 2 with the conductor 3 disposed therebetween and a top layer 6 (comprising a textile tape or a plastic film), it should be evident that all features shown in FIGS. 16 to 19 may be analogously applied for all other embodiments showing different seam tapes.
[0104] The elongated seam tape shown in the embodiments of FIGS. 16 to 19 all comprise an electrical connector connected to one end of the conductor 3. The electrical connector comprises a crimp sleeve 21 attached to the end of the conductor and a connector element 22 longitudinally protruding from the lumen of the seam tape. While the specific connector element 22 shown in FIGS. 16 to 19 comprises a rivet stud 22a, a metal ring 22b and a snap button 22c, other connector elements may be used in combination with the inventive seam tape. For example, the snap button 22c may be replaced with a magnetic button.
[0105] Moreover, the seam tape of the present invention may also comprise a connector without any fabric being present. A preferred embodiment of such a seam tape 101 is shown in FIG. 20. The conductor 3 of the seam tape is mechanically and electrically connected to a crimp sleeve 21 and the crimp sleeve is connected to a connector element 22 protruding out of the lumen of the seam tape in the longitudinal direction.
[0106] In the embodiment shown in FIG. 20, the first and second layers 1 and 2 comprise an adhesive material and the conductor 3 is sealed from the environment by the adhesive material completely surrounding the crimp sleeve 21. In the embodiment shown in FIG. 20, the end of the crimp sleeve 21 proximate to the corresponding end of the seam tape 101 is flush with the end of the first and second layers 1 and 2 with the connector element 22 starting at the very end of the lumen of the seam tape.
[0107] FIG. 21 shows an alternative embodiment of the inventive seam tape 101 with a connector, where a portion of the connector element 22 is positioned within the lumen of the seam tape and where the crimp sleeve 21 is thus completely retracted into the lumen, which may then be sealed by the connector element and the adhesive layers 1 and 2 surrounding the connector element. Advantageously, the connection between the conductor 3 and the crimp sleeve 21 is thereby completely embedded in the seam tape, providing improved sealing as well as mechanical and electrical stability.
[0108] Preferably, the end of the crimp sleeve 21 proximate to the respective end of the lumen 4 has a distance d to said end of the lumen of at least 1 mm, preferably of at least 3 mm, more preferably of at least 5 mm. In case of a longitudinally symmetric placement of the conductor 3 within the lumen 4, said distance d corresponds to one half of the difference between the lengths of the lumen and the conductor.
[0109] In the embodiments shown in FIGS. 16 to 19, the first and second layers 1 and 2 comprise an adhesive material and the lumen is sealed by the adhesive material completely surrounding the crimp sleeve 21. In an alternative embodiment (similar to FIG. 21), a portion of the connector element 22 may be positioned within the lumen, which may then be sealed by the connector element and the adhesive layers surrounding the connector element.
[0110] Moreover, in all embodiments shown in FIGS. 16 to 19, the adhesive material of the second layer 2 is directly adhesively bonded to the fabric 20. Thus, the crimp sleeve 21 is also mechanically fixed to the fabric 20 by means of the adhesive layer 2. An additional fixation is achieved by means of the rivet stud 22a of the connector element 22 which extends through the fabric 20 and, accordingly, mechanically fixes the connector element 22 and, thus, the entire connector to the fabric 20. It should be noted that components of the connector element may also extend over the seam tape for further mechanical fixation (not shown). For example, if the connector element comprises a rivet-like snap button assembly, the top and bottom parts of the snap button assembly may extend over the seam tape, thus mechanically fixating the seam tape ends between the top and bottom parts of the snap button.
[0111] Moreover, all embodiments shown in FIGS. 16 to 19 comprise an optional reinforcement layer which further mechanically stabilizes the connection between the connector and the seam tape on the one hand and the connector and the fabric on the other hand.
[0112] In the embodiment shown in FIG. 16, a reinforcement layer 23 (which may, for example, be a textile reinforcement layer) is bonded directly to the top layer 6, a part of the connector element 22 and the fabric 20 by means of an additional adhesive layer 24. Accordingly, an end of the seam tape 116 shown in FIG. 16 is enclosed between the fabric 20 on the one hand and the reinforcement layer 23 on the other hand.
[0113] However, a reinforcement layer 25 may also be provided adjacent to the fabric 20 as shown in FIG. 17. In this case, the reinforcement layer 25 is bonded to the fabric 20 by means of an additional adhesive layer 26. On the opposite side of the reinforcement layer 25, said reinforcement layer 25 is bonded to the crimp sleeve 21 by means of the adhesive layer 2. Due to its positioning between the crimp sleeve 21 and the fabric 20, the reinforcement layer 25 may also be in mechanical contact with the connector element 22, the rivet stud 22a of which extends through the reinforcement layer 25 as shown in FIG. 17.
[0114] Of course, the concepts shown in FIG. 16 and FIG. 17 may also be combined as shown in FIG. 18.
[0115] Finally, a reinforcement layer 27 may also be provided on the opposite side of the fabric 20 as shown in FIG. 19. In this case, the end of the seam tape is enclosed between reinforcement layers 23 and 27 with reinforcement layer 27 being bonded to the fabric 20 by an additional adhesive layer 28. Again, the rivet stud 22a of the connector element 22 extends through the reinforcement layer 27 as shown.
[0116] As is evident from the above, the present invention allows for a robust connection to conductors embedded in seam tapes. In particular, the embodiments discussed provide for robustness of the electrical contact to mechanical stresses, robustness of the mechanical contact to mechanical stresses, avoidance of damage to the soft conductor in the transition region between rigid and soft conductors and ease of production and cost of the connector solution. Inter alia, the connector of the present invention disconnects the electrical contact from the mechanical fixation, providing a sufficient strain relief mechanism. In the simplest embodiment, the connector may be based on commercially available crimp-type sockets or ring-tongue terminals. The sleeve of these crimp-type sockets may be inserted directly into the lumen of the seam tape. The crimp is then closed and the tape is ready for lamination. After lamination, rivet buttons may be applied with the shaft of the rivet stud inserted into the ring of the crimp-type socket. Electronic components can then be connected via the buttons. Additional strain relief is obtained due to use of, for example, a more rigid textile as reinforcement layer as discussed above.
