SEAM TAPES INCLUDING FIBER BASED CIRCUITRY

Abstract

Systems and methods which make use of metalized fabrics and threads as wiring by attaching them to clothing as a part of a seam tape. The attachment may occur at the seam through a seam tape which is already being used with the garment, or it may occur by attaching the seam tape to a seam, or simply a surface of the garment, to position the wiring in the desired location.

Claims

1. A seam tape comprising: a top layer; an underlayment layer; an adhesive layer arranged between said top layer and said underlayment layer; and an electrically conductive wire, said wire being positioned within said adhesive layer and between said underlayment layer and said top layer; wherein, said seam tape is configured to bond to a fabric placed proximate said underlayment layer via adhesive in said adhesive layer.

2. The seam tape of claim 1 wherein said wire comprises a metallic thread.

3. The seam tape of claim 1 wherein said wire comprises a metallized fiber.

4. The seam tape of claim 1 wherein said wire comprises an elongated strip of metalized fabric.

5. The seam tape of claim 4 wherein said elongated strip includes ends with a larger per unit area than a connection between said ends.

6. The seam tape of claim 5 wherein said top layer includes a hole therethrough so a portion of at least one of said ends is electrically accessible through said hole.

7. The seam tape of claim 4 wherein said top layer includes a hole therethrough so a portion of said metalized fabric is electrically accessible through said hole.

8. The seam tape of claim 1 wherein said adhesive is a thermosetting adhesive.

9. The seam tape of claim 1 wherein said adhesive is a sonic bonding adhesive.

10. The seam tape of claim 1 wherein said top layer is water resistant.

11. A seam tape comprising: a top layer; an adhesive layer arranged on said top layer; and an electrically conductive wire, said wire being positioned within said adhesive layer; wherein, said seam tape is configured to bond to a fabric placed proximate said adhesive layer via an adhesive in said adhesive layer.

12. An article of clothing comprising: fabric forming said clothing; and a seam tape including: a top layer; an adhesive layer arranged on said top layer; and an electrically conductive wire, said wire being positioned within said adhesive layer; wherein, said seam tape is bonded to said fabric via an adhesive in said adhesive layer.

13. The article of clothing of claim 12, wherein said seam tape is positioned on an interior of said article of clothing.

14. The article of clothing of claim 12, wherein said seam tape is positioned on a sewn seam of said article of clothing.

15. The article of clothing of claim 12, wherein said seam tape further comprises an underlayment layer with said adhesive layer positioned between said top layer and said underlayment layer, and said underlayment layer is in contact with said fabric forming said clothing.

16. The article of clothing of claim 12 wherein said wire comprises a metallic thread.

17. The article of clothing of claim 12 wherein said wire comprises a metallized fiber.

18. The article of clothing of claim 12 wherein said wire comprises an elongated strip of metalized fabric.

19. The article of clothing of claim 18 wherein said elongated strip includes ends with a larger per unit area than a connection between said ends.

20. The article of clothing of claim 18 wherein said top layer includes a hole therethrough so a portion of said metalized fabric is electrically accessible through said hole.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0044] FIGS. 1A and 1B show a front angular perspective view of two embodiments of a seam tape including metalized fibers. In FIG. 1A the metalized fibers are in the adhesive layer while in FIG. 1B they are in an underlayment layer.

[0045] FIG. 2 shows a photograph of a seam tape including metalized fibers.

[0046] FIG. 3 shows a photograph of a seam tape including metalized fibers or fabric in place over a seam between two attached fabrics. The metalized components are not visible as they are hidden by the top layer of the seam tape.

[0047] FIG. 4 shows a photograph of an embodiment of a seam tape with metalized fabric wires placed therein. The top layer in this case is transparent.

[0048] FIG. 5 shows a photograph of an embodiment of a seam tape with metalized fabric wires and cutouts for connections in an opaque top layer.

[0049] FIG. 6 shows a similar embodiment to that of FIG. 5 but the top layer is transparent.

DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0050] As discussed herein, the terms thread, yarn, and fiber are often used interchangeably although those terms are often provided with specific meaning in the art. The reason for this is because the processes discussed herein can be used with any of these items. For the most part, however, this disclosure will generally attempt to use the terms as follows. A filament will be considered a single strand synthetic fiber or polymer extrusion or a single strand from a natural fiber (e.g. a single strand of cotton or hair of wool). Meanwhile a yarn, thread, or filament bundle is usually referring to a structure comprising a number of filaments combined together. For example, filaments which are spun or otherwise interconnected, entangled, or arranged together form a filament bundle or yarn. A thread herein may comprise, but is not limited to, staple, monofilament, spun yarn, co- or tri-extruded filaments of any geometry, microfiber, multifilament yarn, sewing yarn, or any other fiber used to connect one part of a piece of fabric with another. A fiber will generally be used to refer to both filaments and threads jointly.

[0051] Similarly, a fabric will generally be a plurality of filaments which are usually formed into yarns (although they may be used directly) and the yarns are then formed into a generally planar structure through weaving, sewing, darning, molding, or any other process known to those of ordinary skill in the art. Fabrics, will generally be combined with threads through sewing (although adhesives or other materials may be used in other cases) in order to turn the fabric into clothing.

[0052] When this disclosure is discussing the inclusion of metalized fibers in a fabric, metalized fibers themselves, or other metalized components of a fabric, the contemplation is generally that a metalized component be provided which meets certain electrical criteria and requirements regardless of how the metalized fiber doing the electrical transmission is actually constructed. In most cases, metalized fibers will comprise a natural or synthetic fiber either coated or impregnated with metallic particles to a sufficient degree to allow it to transmit an electrical impulse of size and duration sufficient for a prescribed task for which it is to be used without a loss which is not known and compensated for by the electrical communication protocol or other components in the circuit.

[0053] Exactly how such fiber is constructed or what it's capabilities are is generally not relevant to the present disclosure as the present disclosure is directed to how to mount a desired fiber and/or fabric that meets the necessary electrical criteria into a piece of clothing or onto a piece of fabric. However, it would be recognized by one of ordinary skill that fibers impregnated with metal will generally be more resilient to damage than those that are coated with metal and, therefore, the present disclosure will usually use as an example a fiber metalized by coating recognizing that the principle systems and methods discussed herein could also be applied to a fiber impregnated with metal.

[0054] In generating smart clothing, it is generally the case that the entire clothing article is not intended to be metalized in order to provide for electrical communication. Complete metallization will generally not work as the electrical communication cannot be easily carried from a distinct sensor to a distinct receipt point as there is no line of communication. Instead, the clothing will generally include a plurality of discrete wires within its fabric. These wires will generally be physically separate, insulated from each other, and will effectively act as wiring between distinct components such as, but not limited to, (micro)processors, sensors, and transceivers which will be located at different points in the clothing, or may be plugged into specific attachment points in the clothing.

[0055] The wires will carry a variety of electrical signals which can range from power transmission (generally in the firm of direct current (DC) transmission) to communication signals using any available wired electrical communication standard or method. The wires can comprise a number of different materials. In more traditional designs, the wire is often a single metalized fiber acting in the form of a single strand of metallic wire. For example, a fiber may be formed with a metallic wire core and/or multiple layers of metallization and/or insulation (including the filaments themselves) to act as a shielded or co-axial cable. Alternatively, fibers may be arranged together in the form of a twisted pair cable such as is used in category (e.g. CAT5, CAT6, or CAT7) cable to provide for data communication. Further, as discussed later in this disclosure, small strips of metalized fabric can be used as wires or arranged to be wires or form the components of wires.

[0056] Regardless of how the metalized fibers are arranged to form wires, metalized fibers will generally have some characteristics which are considered detrimental to their use in clothing. In particular, the primary problems contemplated by the systems and method herein are how to hide the wires from being externally visible on the clothing and how to protect the fibers from damage due to frictional wear and liquid (specifically water) exposure.

[0057] For this reason, the present application generally contemplates that protections for the metallization of the fiber will be supplied in the form of seam tape. Seam tape is a well-known structure used in the construction and repair of garments, and particularly waterproof and water resistant garments, to inhibit water passage through sewn seams of the garments or to repair rips or other damage. Seam tape in garment construction is commonly used in hard shell garments where the shell of the garment is made of a material which has generally been made to inhibit liquids (specifically liquid water) from passing through its structure. Seam tapes are generally known in the art and some examples are provide in U.S. Pat. Nos. 6,497,934 and 8,518,511 as well as PCT Patent Application Publication WO 91/07278. The entire disclosure of all these references is herein incorporated by reference.

[0058] Typically, seam tapes are used to cover a sewn seam of a garment. When two individual fabric pieces are joined (generally by sewing), the line of thread is usually covered by the seam tape by utilizing an adhesive layer of the seam tape to bond the tape to the area of the seam. The adhesive is often thermosetting, and heat is applied to the seam tape to bond the seam tape to the two pieces of fabric and seal in the thread and all associated needle holes. Thus, the resultant piece of clothing has a seam connecting two pieces of fabric, but the possible points of weakness from the sewing construction have been sealed by the tape. In the present case, seam tape is used as a methodology to provide for wiring in a garment to allow for electrical conductivity to occur. Generally, the wiring is provided by having individual or composite metalized fibers, threads, or fabrics be placed within or in contact with the adhesive of the seam tape.

[0059] FIGS. 1A and 1B provide for embodiments of how a seam tape (100) can be used with metalized fibers and particularly threads or small thread structures. Seam tape (100) generally comprises a multi-layer structure with at least a top layer (101) which is chemically bonded to an adhesive layer (103). The top layer (101) is commonly fabric or other material used in garment construction such as vinyl or plastic sheeting. In many seam tapes (100) the top layer (101) is designed to be waterproof or highly water resistant. The adhesive layer (103) may be made up of any type of adhesive, but is often a thermosetting adhesive or sonically bonding adhesive which is chemically or otherwise bonded to the top layer (101) when the seam tape (100) is manufactured. In this way, the adhesive layer (103) and top layer (101) are generally inseparable from each other during normal installation and wear.

[0060] In the seam tapes (100) of FIGS. 1A and 1B, the tapes (100) include a third underlayment layer (105). This underlayment layer (105) is optional but is commonly used to provide additional wear resistance and transition with the fabrics to which the seam tape (100) is connected. The underlayment layer (105) will generally be designed so that the adhesive in the adhesive layer (103), when activated, can flow through the underlayment layer (105) and still bond with the underlying fabric of the clothing.

[0061] As can be seen in FIGS. 1A. and 1B, the wires (107) which will be used to carry electrical signals are generally embedded in the adhesive layer (103) as in FIG. 1A, or may be woven into the underlayment layer (105) as in FIG. 1B. The wires (107) will preferably be metalized fibers (107) either as threads or as thread constructs designed to form particular wire arrangements (e.g. co-axial or twisted pair arrangements). However, elongated metal structures, can be used in addition or instead of metalized fibers in different embodiments. These fibers (107) will generally comprise a natural or synthetic filament bundle which has been metalized with any metal of interest to make it electrically conductive.

[0062] In FIG. 1A, the fibers (107) are positioned in the adhesive layer (103). They will generally be placed within the adhesive when it is chemically bonded to the top layer (101). However, if the underlayment layer (105) is not present, the fibers (107) may actually be presented to the adhesive when the seam tape (100) is bonded to another piece of fabric. Specifically, the fibers (107) may be positioned on the underlying fabric or garment, the seam tape (100) may be placed thereon with the adhesive layer (103) in contact with the fibers (107). When the seam tape (100) is bonded to the garment or fabric in the traditional manner, the adhesive in the adhesive layer (103) will flow over the fibers (107) and contact the underlying fabric. Regardless of which of the above methods is used, it should be apparent that the fibers (107) will generally be encased within the adhesive layer (103) once the seam tape (100) is applied to a fabric or garment.

[0063] The structure of FIG. 1A where the metalized fiber or fibers (107) are in the adhesive layer (103) of the seam tape (100) after the seam tape (100) has been attached to the underlying fabric or garment should be readily apparent. In the first instance, the fibers (107) are not visible from either side of the garment. From the first side, they are blocked by the top layer, in the second they are blocked by the fabric of the garment. Thus, the fiber's (107) presence is not readily noticeable. This is shown, for example, in FIG. 2 where only exposed ends of the fiber (107) are visible and FIG. 3 where only the top layer (101) is visible.

[0064] By placing the metalized fibers (107) in the adhesive layer (103) of the seam tape (100), the adhesive can act as an insulator for the fibers (107) and they are also generally held in position relative to each other within the seam tape (100). Thus, electrical properties of the fibers (107) can be preserved. The seam tape (100), because it is also designed to be waterproof in most instances, also serves to protect the fibers (107) from degradation due to fluid contact. Specifically, the seam tape (100) (and underlying fabric) will resist penetration by fluid to get at the fibers (107) presuming the top layer (101), underlayment layer (105), or underlying fabric are considered waterproof. Further, the adhesive itself will generally also resist such penetration. Thus, the fiber (107) is generally protected from any form of contact with liquid water and associated degradation.

[0065] Generally, the fibers (107) will be allowed to extend beyond the ends of the seam tape (100) as indicated in FIGS. 1A and 1B but also shown in FIG. 2. The ends of the fibers (107) in this case can be used to make electrical connection with other components included in the garment. This can include, but is not limited to, sensors, processors, communication apparatus, power sources, and other wiring. How the wiring is hidden by the seam tape is best illustrated in FIG. 3.

[0066] While the above disclosure has focused on the use of individual metalized fibers (107) or wire-like metalized fiber structures made from specific fibers, FIGS. 4 through 6 provide for alternative embodiments of seam tape which utilize a wire which is a small generally planar construct of metalized fabric. In FIGS. 4 through 6, individual fibers (107) or thread structures are not used for conductivity. Instead, small strips of metalized fabric (207) which include a plurality of fibers are used. The metalized fabric (207) may be formed by any method known to those of ordinary skill, but will generally be mostly or completely metalized. Thus, the metalized fabric (207) can be formed from a plurality of metalized fibers (107) that are woven or otherwise connected together to form a fabric, or the metalized fabric (207) may be formed by other methods such as through the interknitting of metalized and non-metalized fibers of through metallization of a fabric in its finished constructed form.

[0067] The strips of fabric (207) generally comprise generally rectilinear structures with one dramatically elongated dimension. The elongation serves to provide the run of wire and for all intents and purposes the wire should be treated as an approximately planar strip of conductive material. These strips of metalized fabric (207) will also generally be positioned within the adhesive layer (103) of a seam tape (100) through any or all of the constructions contemplated for use with metalized fibers (107) above, and the seam tape (100) can be placed into a garment as discussed above in conjunction with individual fibers (107). Metalized fabrics (207) may also be formed into other specific wire-like structures in much the same manner as metalized fibers (107).

[0068] As can be best seen in FIGS. 5 and 6, an additional advantage of using metalized fabric (207) as the wire within a seam tape (100) is that the metalized fabric (207) can also directly provide sensor points. Depending on need and purpose, the metalized fabric (207) itself may be sufficient to detect electrical differences corresponding to desired physiological changes of the user. Alternatively, the metalized fabric (207) can directly provide a connection point for a sensor. Regardless, as can be seen in FIGS. 5 and 6, holes (217) can be cut in the top layer (101) to allow a small amount of the fabric (207) to be accessible through the top layer (101). These small spaces serve as sensor access points, sensors, or as connection points for other structures, such as batteries and processors. Specifically, they can provide a point of electrical connection through the top layer (101). As can be seen in FIGS. 5 and 6, the fabric (207) under the holes (217) may be of a generally larger per unit area than the fabric (207) forming the wires. This allows for a larger connection or sensor point, if desired.

[0069] It should be apparent from the above that placing either metalized fibers (107), or strips of metalized fabric (207), in or on the adhesive layer (103) or in the underlayment layer (105) of a seam tape (100) provides for many benefits in the wiring of clothing. In the first instance, many articles of clothing already utilize seam tapes as part of their construction for other reasons. In these types of clothing constructions, inclusion of the wiring in the seam tape provides for very little incremental change in the design of the clothing, while at the same time providing wiring over at least a portion of the clothing. Thus, placing the wires within the seam tapes which are already being used can provide for a large amount of wiring which has little to no effect on the feel of the clothing.

[0070] Further, the fibers (107) and fabrics (207) used herein are often no stiffer or less responsive than the seam tape (100) materials already are (once bonded). Thus, any change in feel is primarily due to the use of seam tape at all, and thus, the wiring inclusion provides for very little effect on feel. Further, because the top layer (101) can be opaque (and matched to the clothing) the wiring in the clothing can effectively be invisible as is it between the top layer (101) and the clothing (301) as best illustrated in FIG. 3.

[0071] The use of metalized fabrics (207) and fibers (107) will generally, however, not be limited to their inclusion as part of the installation of seam tapes (100) which are being installed for other reasons. This would limit the position of the wiring to existing seams and related structures, which, while it may serve to provide a communication backbone or wiring scheme in certain clothing and applications, does not necessarily work for a last mile connection to the individual sensors or other electronics in all cases.

[0072] The seam tape (100) structure, however, can still provide benefits to installation of wiring at any point in fabric as is best illustrated in FIGS. 5 and 6. Specifically, the seam tape (100) may be placed directly on any fabric surface (301) of the garment. Generally, this will be on an inner surface so that none of the top layer (101), the metalized fabric (207) of fiber (107), the adhesive layer (103), or the underlayment layer (105) is visible from the outside of the clothing.

[0073] As discussed above, the top layer (101) of the seam tape (100) is commonly a fabric, sheet plastic, or other structure. As such, a top layer (101) may also be provided with good feel against a user's skin when paired with the fabric (301) of the clothing or may have chemical agents that improve feel placed thereon. In this arrangement, The seam tape (100) need not be applied to a seam necessarily, but may be placed anywhere on any surface of the garment. This allows for the wiring to be positioned at virtually any location within the garment and it will appear as seam tape, not metalized wiring. Further, as the metalized fiber (107) or fabric (207) is not sewn into the garment, but is instead taped to the inside of it, the metalized fiber (107) or fabric (207) is generally not visible (unless it there is a hole (217) provided as contemplated elsewhere in this disclosure).

[0074] It should be recognized that for purposes of water protection of the metalized fiber (107) or fabric (207), the adhesive layer (103) and top layer (101) can only go so far as to provide waterproofing when the seam tape (100) is applied to a fabric surface (301) which is not waterproof as water could go through the surface (301). However, in such a scenario, the use of metalized fabric (207) as the wire as shown in FIGS. 4 through 6 can provide additional benefit over the use of individual metalized fibers (107). A metalized fabric (207) is generally a much more macro scale structure than an individual fiber (107) and will usually include a substantially greater amount of metal. Further, electric flow will generally only be interrupted if loss of metallization occurs at a point completely across the wire. With a metalized fabric (207) this requires a generally much larger loss of continuous metallization to create. Further, because the metalized fabric (207) can be metalized in a different fashion to an individual fiber (107) (for example it can be coated in metal after it is constructed), the metallization in fabric may be more resistant to damage from contact with liquids because the manner of metallization itself assists in resisting damage from exposure to liquids.

[0075] Thus, in an embodiment, the top layer (101) of the seam tape (100) and/or the clothing fabric (301), are not waterproofed at all. Instead, water contact is allowed to go through one or more of these structures and contact the metalized fabric (207) between. In this case, however, the contact may not be overly detrimental as the fabric (207) can accept much more laundering without losing sufficient electrical characteristics to be unviable. Thus, the fabric (207) arrangement of FIGS. 4 through 6 may be much more resistant to laundry damage than the single metalized fiber (107) structures of FIGS. 1A through 2.

[0076] Throughout this disclosure, relative terms such as generally, about, and approximately may be used, such as, but not necessarily limited to, with respect to shapes, sizes, dimensions, angles, and distances. One of ordinary skill will understand that, in the context of this disclosure, these terms are used to describe a recognizable attempt to conform a device to the qualified term. By way of example and not limitation, components such as surfaces described as being generally parallel will be recognized by one of ordinary skill in the art to not be, in a strict geometric sense, parallel, because, in a real world manufactured item, no surface is generally never truly planar as a plane is a purely geometric construct that does not actually exist, and no component is truly planer in the geometric sense. Thus, no two components of a real item are ever truly parallel, as they exist outside of perfect mathematical representation. Variations from geometric descriptions are inescapable due to, among other things: manufacturing tolerances resulting in shape variations, defects, and imperfections; non-uniform thermal expansion; design and manufacturing limitations, and natural wear.

[0077] There exists for every object a level of magnification at which geometric descriptors no longer apply due to the nature of matter. One of ordinary skill will understand how to apply relative terms such as generally, about, and approximately to describe a range of variations from the literal meaning of the qualified term in view of these and other considerations as well as that use of such mathematical terms is not intended to mean their strict mathematical relationship, but a general approximation of that relationship in the real world.

[0078] Further, use in this description of terms such as forward and backward do not actually require that certain surfaces or objects be closer or further away from a surface at any given time or to denote a necessary arrangement of components or components relative to a user. Instead, they are generally used to denote opposite directions in conjunction with the standard arrangement of the FIGS. provided herein so as to give relative positioning of elements. Similarly, terms such as inside and outside, left and right, and top and bottom are used to show relative directions or positions as opposed to absolute location relative any other component or a human user or observer.

[0079] It will further be understood that any of the ranges, values, properties, or characteristics given for any single component of the present disclosure can be used interchangeably with any ranges, values, properties, or characteristics given for any of the other components of the disclosure, where compatible, to form an embodiment having defined values for each of the components, as given herein throughout. Further, ranges provided for a genus or a category can also be applied to species within the genus or members of the category unless otherwise noted.

[0080] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.