Improvements relating to a flexible sensor and an associated production method.

Abstract

Improvements relating to a flexible sensor and a method of producing the same. A flexible fabric device for use in thermal applications comprises a flexible fabric (100) consisting of a combination of a first set of junctions (200, 400) and a second set of junctions (202, 402) each formed from a respective first and second material, each having a known first thermoelectric coefficient and a known second thermoelectric coefficient, the first set of junctions (200, 400) being separated from the second set of junctions (202, 402) by a third material and one of the following being generated based on the first and second thermoelectric coefficients: - an electrical response between the first set of junctions (200, 400) and the second set of junctions (202, 402) as a function of a different temperature gradient therebetween;and - a thermal response between the first set of junctions (200, 400) and the second set of junctions (202, 402) based on an electrical gradient difference between them. Figure for abstract: Figure 7;

Description

Title of the invention: Improvements relating to a flexible sensor and an associated production method. Technical field of the invention

[0001] The present invention relates to a flexible sensor and method of manufacturing the same, particularly, but not exclusively, to a thermal gradient energy sensor formed from a fabric or textile. Technical background

[0002] Sensors are used in a wide variety of situations and come in many different types or forms. One particular area of sensor development exists in the form of fabric or textile sensors made from so-called technical yarns. A technical yarn is a thread, cable, fiber, or strand of material that, when included in a fabric or textile, produces a technical functionality greater than that envisaged by simply forming a fabric or textile. For example, a yarn may comprise different types of materials, such as a metal or an insulator, woven or sewn together to form a fabric article that can also serve as a sensor. Textile materials made from yarns with the ability to generate and transmit electrical energy are well known. A number of different techniques have been found useful for implementing this technology.

[0003] One area where fabric sensors could be of interest is in measuring the thermal gradient of an item. The use of a fabric sensor is particularly attractive because it is flexible and can be easily conformed or molded to the surface of an item where measurement by a sensor may be required. Therefore, the sensor is in very close relationship with the item and the measurements can be very accurate.

[0004] There is a need for a better sensor made from a fabric that is durable, flexible and reliable. The present invention therefore aims to improve the production and implementation of electrically conductive textile materials comprising an associated sensor. Summary of the invention

[0005] The present invention according to at least one of its embodiments relates to a flexible fabric device for use in thermal applications, characterized in that it comprises a flexible fabric consisting of a combination of a first set of junctions and a second set of junctions each formed from a respective first and second materials, each having a first known thermoelectric coefficient and a second thermoelectric coefficient, the first set of junctions being separated from the second set of junctions by a third material and one of the following being generated based on the first and second thermoelectric coefficients:

[0006] - an electrical response between the first set of junctions and the second set of junctions depending on a different temperature gradient between them; and

[0007] - a thermal response between the first set of junctions and the second set of junctions based on an electrical gradient difference between them.

[0008] According to at least one embodiment of the invention, the first thermoelectric coefficient is the Seebeck coefficient.

[0009] According to at least one embodiment of the invention, the flexible fabric device is a sensor for determining a thermal gradient (d) in a predetermined environment.

[0010] According to at least one embodiment of the invention, the first thermoelectric coefficient is the Peltier coefficient.

[0011] According to at least one embodiment of the invention, the flexible fabric device is an element for heating or cooling an environment.

[0012] According to at least one embodiment of the invention, the first set of junctions is formed in a first layer and the second set of junctions is formed in a second layer and the first and second layers are separated from each other by a layer of the third material.

[0013] According to at least one embodiment of the invention, the first set of junctions and the second set of junctions are respectively hot and cold junctions.

[0014] According to at least one embodiment of the invention, the first set of junctions and the second set of junctions are formed by sewing fibers of the respective materials together to form stitches or knots.

[0015] According to at least one embodiment of the invention, the density of the first set of junctions and the second set of junctions is associated with an operating precision of the device in use.

[0016] According to at least one embodiment of the invention, the first material is chosen from the group comprising: carbon, aluminum, scandium, tungsten, nickel;

[0017] and the second material is chosen from the group comprising: silver, gold, iron, cadmium, copper, zirconium, selenium, chromium, lithium.

[0018] According to at least one embodiment of the invention, the third material is chosen from the group comprising polymers, charged polymers, doped polymers, copolymers whose hardness or elasticity can be modulated, resins, ethylene-vinyl acetate (EVA), polystyrene (PS), polyethylene (PE), polypropylene (PP), po- lycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), high impact polystyrene (SB), and nylon.

[0019] The invention according to at least one of its embodiments also relates to a method of forming a flexible fabric device from a flexible fabric characterized in that it comprises the following steps:

[0020] forming first junctions in a layer of a first material having a first thermoelectric coefficient;

[0021] forming the second junctions in the layer of a second material having a second thermoelectric coefficient;

[0022] fusing the layers using a thermoactive material; and

[0023] exposing the junctions in the layers to allow the first and second materials to react to heat, wherein the formed flexible fabric is configured to one of the following:

[0024] generating an electrical response between the first junctions and the second junctions based on a temperature gradient difference therebetween; and

[0025] generating a thermal response between the first junctions and the second junctions based on an electrical gradient difference therebetween.

[0026] According to at least one embodiment of the invention, the first and second junctions are formed by sewing a thread having a predetermined configuration of first and second junctions into the flexible fabric.

[0027] According to at least one embodiment of the invention, the first and second materials comprise a removable coating.

[0028] According to at least one embodiment of the invention, the coating is water soluble and the method further comprises removing the water soluble material using a water bath in which the water soluble material can dissolve.

[0029] According to at least one embodiment of the invention, the method further comprises a step of exposing the junctions in the layers to allow the first and second materials to be heat sensitive, and a step of cutting the removable coating from the first and second materials. Brief description of the figures

[0030] Other characteristics and advantages of the invention will appear during the reading of the detailed description which follows for the understanding of which reference will be made to the appended drawings in which:

[0031] [Fig.l] is a simplified diagram of a sensor, according to one aspect of the invention.

[0032] [Fig.2] is a cross-section of the diagram of [Fig.l];

[0033] [Fig.3] is a more detailed diagram of the sensor of [Fig.l], according to one aspect of the invention;

[0034] [Fig.4] is an example of how the threads of a fabric are sewn or knotted together according to the present invention;

[0035] [Fig.5] and [Fig.6] show how the fabric may be sewn using a sewing machine or the like, according to one aspect of the invention;

[0036] [Fig.7] is a more detailed view of the sensor which shows how the fabric can be used as a sensor, in accordance with one aspect of the invention. Detailed description of the invention

[0037] The present invention relates to a fabric sensor capable of measuring a thermal gradient or other type of temperature profile, by placing the sensor against or near an item for which a measurement is required. The fabric is made of a combination of yarns each having a particular electrical characteristic. For example, the fabric can be made of any combination of materials and types, such as a conductive yarn interwoven with a yarn of conductive material. The possibilities are immense.

[0038] Thus, for example, at least one of the fibers comprising the fabric is a fiber comprising a first yarn of electrically conductive material and a second yarn of deformable thermoformable material. For example, the first and second yarns are interwoven. More than two yarns may be used to form the fabric, for example, a third textile yarn may be added to the first and second yarns when combining them. The fabric is shown as being woven, but it could be joined by knitting or in some other way, combined or simply arranged in close proximity to each other.

[0039] It should be noted that any material compatible with thermoforming can be used in the present invention, such as polymers, filled polymers, doped polymers, copolymers whose hardness or elasticity can be modulated, resins, ethylene-vinyl acetate (EVA), polystyrene (PS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), high impact polystyrene (SB), Nylon, etc. The polymers or resins can be filled with EVA to modulate the elasticity of the fibers or yarns that make up the fabric.

[0040] The interlacing of the first and second yarns to form a fabric may, for example, be achieved using an overlapping technique. Filix, for example, offers such yarns. Any other technique may also be used. Alternatively, the yarns may be interlaced (manually or by machine) to form one or more fibers.

[0041] The present invention uses a fabric configured to take advantage of a phenomenon known as the Seebeck effect. The Seebeck effect is an effect in which a force Electromotive force (EMF) develops across two points on an electrically conductive textile when there is a temperature difference between them. The generated electromotive force gives rise to a voltage and an associated current between the connections within the conductive textile. The ability to detect current and / or voltage gives rise to many useful applications. The Seebeck effect is due to the formation of two different types of electrical junction by the combination of a first and a second wire, these wires having a different Seebeck coefficient.

[0042] As described, aspects of the invention utilize the Seebeck effect and it will be appreciated that a similar flexible fabric device utilizing the Peltier effect is also achievable using the flexible fabric of the present invention. The Seebeck effect is based on the creation of electricity between a thermocouple or junction when the ends are subjected to a temperature difference between them. The Peltier effect is an opposite effect and occurs when a temperature difference is created between the junctions by applying a voltage difference across the terminals. A hot surface in contact with the cold junction will be cooled and a cold surface in contact with the hot junction will be heated.It will be understood that the Seebeck and Peltier effects are opposites of each other, and that the Peltier effect can be used to apply heat and cold rather than to detect them, but it essentially works in the same context and using similar or identical materials.

[0043] Generally speaking, the Seebeck and Peltier effects have in common that they are effects based on a thermoelectric effect and a coefficient associated with the effect can be assigned to different materials, allowing one or the other to be used in many thermoelectric devices and applications. The thermoelectric effect and associated coefficients can be used in different thermoelectric devices for different functions. For example, the Seebeck effect can be used in devices to determine a temperature difference between different locations and / or junctions, such as the hot and cold junctions described herein. In another example, the Peltier effect can be used in devices to apply or remove heat from a situation or environment.

[0044] [Fig.l] shows a flexible fabric 100 which, in this case, is attached to a fluid carrying pipe 102 in order to be used as a sensor for measuring a thermal gradient. [Fig.2] is a cross-section of [Fig.l] for ease of understanding. The thermal gradient is measured between an inner surface 104 of the sensor compared to an outer surface 106 of the flexible fabric 100. The flexible fabric 100 is made of fibers 108 and 110 interlaced as described above and in more detail below. The fabric is connected to a meter or voltage supply 112.

[0045] The flexible fabric 100 includes junctions where the fibers overlap or are sewn together. The fibers each have a different Seebeek coefficient and the Temperature changes of the underlying pipe generate a current or voltage that can be measured and converted into a temperature difference between the inner and outer surfaces, as described below. The flexible fabric 100 is represented as a patch having a thickness d and a planar surface A. By increasing the surface area or thickness, the heat capture area increases, and thus the amount of energy measured also increases. The size of the flexible fabric 100 can vary depending on use cases and situations. It should be noted that these types of flexible sensors can be added to environments with limited or no accessibility prior to deployment to provide an in-situ sensor for locations where measurement is difficult or inaccessible with other types of sensors.

[0046] The nature of the flexible fabric is now described in more detail with reference to [Fig. 3]. The flexible fabric 100 includes a number of junctions 200 and 202 caused by the combination of the fibers 108 and 110 (not shown in [Fig. 3]). The junctions are a cold junction 200 and a hot junction 202, respectively. The temperature gradient is between the inner and outer surfaces 104 and 106. The voltage or energy produced by the Seebeck effect passes in the y direction. The assembly is provided in the form of a mold where the wires are not directly visible, as they are covered with a sheath or other coating which may be an insulator.

[0047] The nature of the materials used to form the flexible fabric 100 dictates the temperature range of the flexible fabric device, which may range from a few hundred degrees Celsius to several hundred degrees Celsius. For example, a first material may be carbon, which provides a relatively cool junction compared to a second material, silver, which provides a hot junction. Many other materials may be used, including, but not limited to, for the first material: carbon, aluminum, scandium, tungsten, nickel, and for the second material: silver, gold, iron, cadmium, copper, zirconium, selenium, chromium, lithium.

[0048] Generally speaking, the choice of materials will be guided by the differences between the Seebeck coefficients of the materials which are negative or positive, for example iron is given at +11.6 and tungsten at -4.4. The choice will result from a compromise between the Seebeck coefficients and the ability to use these materials in textile solutions.

[0049] [Fig. 4] shows how the nodes or junctions 200 and 202 can be formed using, for example, a thermoplastic-coated carbon fiber 400 and a thermoplastic-coated silver fiber 402. The formed nodes or junctions are hot for the carbon and relatively cold for the silver. The formation of the junctions can result in a yarn or fiber 404 having alternating hot and cold junctions. This yarn can then be used in the formation of the fabric as described in Figures 5 and 6.

[0050] As described elsewhere, aspects of the invention utilize the Seebeck effect and it will beappreciated that a similar flexible fabric 100 utilizing the Peltier effect is also achievable according to the present invention. The Seebeck effect is based on the creation of electricity between a thermocouple or junction when the ends are subjected to a temperature difference therebetween. The Peltier effect is an inverse effect and occurs when a temperature difference is created between the junctions by the application of a voltage difference across the terminals. A hot surface in contact with the cold junction will be cooled and a cold surface in contact with the hot junction will be warmed. It will be appreciated that the Seebeck and Peltier effects are opposites of each other, and that the Peltier effect can be used to apply heat and cold rather than to detect them, but that it operates in essentially the same context and using similar or identical materials.A flexible fabric 100 using the Seebeck effect acts as a sensor and a flexible fabric 100 using the Peltier effect acts as a heating or cooling device. For convenience and to include both effects, the device using the Seebeck or Peltier effect is generally referred to herein as a thermal device.

[0051] Figures 5 and 6 illustrate how the flexible fabric 100 can be machine-made by sewing or combining the fibers necessary for the manufacture of the flexible fiber 100 and associated thermal devices. The device is made from a combination of a first material 500 and a second material 502. The yarn of [Fig. 4] may be used or another yarn having junctions in a different configuration than that shown in [Fig. 4]. The exact nature of the yarn will depend on the number and density of the predetermined junctions. The steps for manufacturing the flexible fiber according to the present invention are as follows.

[0052] In a first step 506, the first material 500 is stitched into a predetermined shape and size to form a first set of seams. The material includes a water-soluble coating. In step 508, the second material is stitched or otherwise combined to form a second set of seams. The first material may include a material having a first Seebeck or Peltier coefficient and the second material is a material having a different second Seebeck or Peltier coefficient. The fibers of the second material may also include a water-soluble coating. The fibers may be provided with a thermally reactive material that softens to join the different layers together and form the flexible fabric. In a step 510, the structure of the layers is heated to fuse the different layers of fibers using a thermoactive material such as the examples described above.In step 512, the layer structure is processed to expose the junction. This may be done by cutting off excess material to expose the junctions or may be based on another exposure method. In step 514, the water-soluble material is removed using a water bath in which the water-soluble material . can dissolve. In step 516, a flexible fabric is obtained having the required hot and cold junctions.

[0053] Although the above steps are presented in one order, a different order may be used in different situations. For example, the junctions may be exposed before being encapsulated in a water-resistant coating. The water-soluble coating may not be necessary or a material dissoluble in another solvent may be used. Other changes and variations will be apparent to those skilled in the art.

[0054] As shown in [Fig.7], the final flexible fabric 100 is produced. The fabric comprises a plurality of nodes or points 600 designated C and F (respectively hot and cold). These are arranged such that the upper surface 602 has hot junctions C and the lower surface 604 has cold junctions F. As seen on face 606, the wires can then be laid on either side of a thermally insulating substrate, with a hot face and a cold face: in this case, the voltage generated between A and B will be negative or positive (inverted) if the faces are inverted. In the case of a thermal gradient, the system becomes a Seebeck effect electrical generator, the power of which depends on the number of junctions. By applying a voltage between A and B, the Peltier effect can be used.

[0055] In the examples shown, the hot and cold junctions are equal in number, which is not necessarily the case. Furthermore, there may be a different sequence of junctions in one or more directions within the layered structure of the material. There may be additional layers, such as several insulating layers inserted between several woven layers, when there are more than two active layers of the first and second material. The combination of junctions (hot and cold) may have any predetermined shape or size depending on the use case.

[0056] In the example presented, there are two active layers separated by a thematically activatable insulating layer, as shown in [Fig.6]. For some applications, there may be additional active layers and, in this case, additional materials having different Seebeck or Peltier coefficients.

[0057] The above description includes various use cases, which are given only as examples, and many other uses can be envisaged.

[0058] The fabric for which the connector is used may also vary and include both conductive and non-conductive materials. The fabric may be woven, non-woven, knitted, or otherwise formed. If the fabric is conductive, at least some of the wires will be made from an electrically conductive material.

[0059] It will be appreciated that there are numerous variations of the features described above which are included within the scope of the appended claims. List of reference signs

[0060] flexible fabric 100

[0061] fluid transport pipe 102

[0062] inner surface 104

[0063] outer surface 106

[0064] fibers 108 and 110

[0065] counter or power supply 112

[0066] cold junction 200

[0067] hot junction 202

[0068] thermoplastic coated carbon fiber 400

[0069] thermoplastic coated silver fiber 402

[0070] wire or fiber 404

[0071] first material 500

[0072] second material 502

[0073] first step 506

[0074] second step 508

[0075] third step 510

[0076] fourth step 512

[0077] fifth step 514

[0078] sixth step 516

[0079] nodes or points 600

[0080] upper surface 602

[0081] lower surface 604

[0082] side 606

Claims

Claims

1. A flexible fabric device for use in thermal applications, characterized in that it comprises a flexible fabric (100) consisting of a combination of a first set of junctions (200, 400) and a second set of junctions (202, 402) each formed from a respective first and second material, each having a known first thermoelectric coefficient and a known second thermoelectric coefficient, the first set of junctions (200, 400) being separated from the second set of junctions (202, 402) by a third material and one of the following being generated based on the first and second thermoelectric coefficients: - an electrical response between the first set of junctions (200, 400) and the second set of junctions (202, 402) as a function of a different temperature gradient therebetween;and - a thermal response between the first set of junctions (200, 400) and the second set of junctions (202, 402) based on an electrical gradient difference between them.;

2. A flexible fabric device according to claim 1, characterized in that the first thermoelectric coefficient is the Seebeck coefficient.

3. A flexible fabric device according to claim 2, characterized in that it is a sensor for determining a thermal gradient (d) in a predetermined environment.

4. A flexible fabric device according to claim 1, characterized in that the first thermoelectric coefficient is the Peltier coefficient.

5. A flexible fabric device according to claim 3, characterized in that it is an element for heating or cooling an environment.

6. A flexible fabric device according to any preceding claim, characterized in that the first set of junctions (200, 400) is formed in a first layer and the second set of junctions (202, 402) is formed in a second layer and the first and second layers are separated from each other by a layer of the third material.

7. A flexible fabric device according to any preceding claim, characterized in that the first set of junctions (200, 400) and the second set of junctions (202, 402) are hot and cold junctions respectively.

8. A flexible fabric device according to any one of the claims previous, characterized in that the first set of junctions (200, 400) and the second set of junctions (202, 402) are formed by sewing fibers of the respective materials together to form stitches or knots.

9. A flexible fabric device according to any preceding claim, characterized in that the density of the first set of junctions (200, 400) and the second set of junctions (202, 402) is associated with an operating accuracy of the device in use.

10. A flexible fabric device according to any one of the preceding claims, characterized in that the first material is selected from the group comprising: carbon, aluminum, scandium, tungsten, nickel; and the second material is selected from the group comprising: silver, gold, iron, cadmium, copper, zirconium, selenium, chromium, lithium.

11. A flexible fabric device according to any one of the preceding claims, characterized in that the third material is chosen from the group comprising polymers, charged polymers, doped polymers, copolymers whose hardness or elasticity can be modulated, resins, ethylene-vinyl acetate (EVA), polystyrene (PS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), high impact polystyrene (SB), and nylon.

12. A method of forming a flexible fabric device from a flexible fabric (100) characterized in that it comprises the steps of: forming (506) first junctions in a layer of a first material (502) having a first thermoelectric coefficient; forming (508) second junctions in the layer of a second material (504) having a second thermoelectric coefficient; fusing (510) the layers using a thermoactive material; and exposing the junctions in the layers to allow the first and second materials to respond to heat, wherein the formed flexible fabric (100) is configured to one of the following: generating an electrical response between the first junctions and the second junctions based on a temperature gradient difference therebetween;and generating a thermal response between the first junctions and the second junctions based on an electrical gradient difference therebetween.;

13. A method according to claim 12, characterized in that the first and second junctions are formed by sewing a thread having a predetermined configuration of first and second junctions into the flexible fabric (100).

14. A method according to any one of claims 12 and 13, characterized in that the first and second materials comprise a removable coating.

15. A method according to claim 14, characterized in that the coating is water soluble and the method further comprises removing (514) the water soluble material using a water bath in which the water soluble material can dissolve.

16. A method according to claim 14, characterized in that it further comprises a step of exposing the junctions in the layers to allow the first and second materials to be heat sensitive, and a step of cutting the removable coating from the first and second materials.

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