Electrical connection
Patent Information
- Application Number
- GB2023013459
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-09-04
- Publication Date
- 2025-03-12
Smart Images

Figure 00000000_0000_ABST
Abstract
Description
CROSS REFERENCE TO RELATED APPLICATIONS This is the first application for a patent directed towards the invention and the subject matter. TECHNICAL FIELD The present invention relates to an apparatus for providing an electrical connection, a wearable item comprising such an apparatus, and a method of manufacturing an apparatus comprising an electrical connection. BACKGROUND OF THE INVENTION There is an increasing demand for smart wearable items, that is, wearable items which include electrical technology to provide electronic outputs. Such wearable items may include operable sensors, wireless technologies, electronics modules or other devices which may enable communication with further external electronic devices. Wearable items are known to be provided with electrical tracks, either in the form of electrical wiring, printed circuits or, as disclosed in GB 2 555 592, by means of a conductive transfer configured to provide an electrical circuit on a wearable item. A problem occurs in such wearable items with connection of the electrical tracks to external electronics devices as wearable connections can lack durability and may easily come dislodged or misaligned, thereby terminating the functionality provided by the wearable item. In practice, where connectors are available, these tend to be complex and expensive and do not provide secure connections to the fabric of the wearable item. In particular, high density connections having a high plurality of connections, such as those required for high density sensors and matrix sensors, can cause particular problems in that a large amount of space can be required to accommodate such connections. This can lead to undesirable effects to the aesthetics and performance of wearable items or similar incorporating connections. BRIEF SUMMARY OF THE INVENTION According to a first aspect of the present invention, there is provided an apparatus for providing an electrical connection, comprising: a flexible material layer; a conductive material forming an electrical circuit printed on said flexible material layer; a substantially rigid stiffening layer; wherein said electrical circuit forms a connection point at an edge of said flexible material layer and said substantially rigid stiffening layer is configured to support said flexible material layer at said connection point. According to a second aspect of the present invention, there is provided a method of manufacturing an apparatus comprising an electrical connection, comprising the steps of: pressing a flexible material layer with an application of heat; printing a conductive material forming an electrical circuit onto a transfer substrate; transferring said conductive material forming an electrical circuit from said transfer substrate to said flexible material layer by means of a further application of heat; forming a connection point at an edge of said flexible material layer with said electrical circuit; and locating a substantially rigid stiffening layer to support said flexible material layer at said connection point. Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings. The detailed embodiments show the best mode known to the inventor and provide support for the invention as claimed. However, they are only exemplary and should not be used to interpret or limit the scope of the claims. Their purpose is to provide a teaching to those skilled in the art. Components and processes distinguished by ordinal phrases such as “first” and “second” do not necessarily define an order or ranking of any sort. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS Figure 1 shows a wearable item including an electrical circuit therein; Figure 2 shows apparatus for providing an electrical connection to a wearable item; Figure 3 shows a method of manufacturing a wearable item comprising an electrical connection; Figure 4 shows an example apparatus in accordance with the present invention; Figure 5 shows a further example apparatus in accordance with the present invention; Figure 6 shows an alternative cross-sectional side view of the apparatus of Figure 5; Figure 7 shows an alternative embodiment of an apparatus for providing an electrical connection to a wearable item; Figure 8 shows an example embodiment of an apparatus including a flexible securing mechanism for securing a connector; Figure 9 shows the embodiment of Figure 8 in perspective view; Figures 10A and 10B show the embodiment of Figures 8 and 9 whereby the flexible securing mechanism secures a connector; Figure 11 an alternative embodiment of an apparatus in accordance with the present invention comprising a housing having a locking mechanism; Figures 12A and 12B show the embodiment of Figure 11 showing a lever mechanism in unlocked and locked positions respectively; Figure 13 shows an exploded view of an apparatus comprising a magnetic spring-loaded connector arrangement; Figure 14 shows an alternative view of the embodiment of Figure 13; Figure 15 shows an arrangement of contact points in the embodiment of Figures 13 and 14; Figure 16 shows a side schematic view of the embodiment of Figures 13 to 15; Figure 17 shows a cross-sectional side schematic of an apparatus and a universal serial bus connector housing; and Figure 18 shows a perspective view of the embodiment of Figure 17. DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION Figure 1 An example wearable item requiring an electrical connection in accordance with the present invention is shown with respect to Figure 1. Wearable item 101 comprises, in this embodiment, underwear in the form of pants comprising incontinence features. Incontinence pants 101 comprise a flexible and / or stretchable material layer 102 which forms the shape of conventional underwear known in the art. In addition, the flexible material layer 102, to address incontinence issues of a wearer, comprises a barrier layer configured to provide a barrier to moisture and which is typically positioned on the outer surface of the flexible material layer 102 to ensure any moisture is retained within wearable item 101. Flexible material layer 102 further comprises an absorbent layer which is configured to absorb any moisture within wearable item 101 and a permeable layer which is configured to allow moisture, such as urine, to pass through to the absorbent layer. In the embodiment of the present invention, wearable item 101 further comprises a conductive material forming an electrical circuit 103 which is suitably printed onto flexible material layer 102. In the embodiment, electrical circuit 103 is consequently provided between the barrier layer and the permeable layer and may be present on the absorbent layer or an additional layer within the flexible material. In the embodiment, electrical circuit 103 comprises pairs of parallel tracks 104 printed within the gusset area 105 of wearable item 101. When moisture crosses the electrical tracks of electrical circuit 103, a drop in resistance is identified such that electrical circuit 103 can be used as a moisture sensor. In the embodiment, electrical circuit 103 is configured to measure the resistance across the electrical tracks and consequently identify and monitor moisture levels and incontinence of a wearer. In the embodiment, microcontroller 106 is positioned in waistband 107 of wearable item 101. This ensures that, in use, as a wearer moves around, microcontroller 106 can be retained in position without negatively affecting the measurement of resistance from electrical circuit 103. In an embodiment, it is appreciated that, in addition to the moisture sensor, other sensors may be incorporated into electrical circuit 103. Electrical circuit 103 may further comprise printed temperature sensors, printed humidity sensors, printed capacitive touch sensors, printed pressure sensors and / or printed electrodes. These examples can be utilised for electrical impedance tomography, electromyography and electrogastrography. In an example embodiment, such sensors are single sensors. In an alternative embodiment, such sensors comprise multiple sensors or matrix type sensors. In an embodiment, waistband 107 is provided with a pocket or fabric loop into which microcontroller 106 can be located. This adds further protection to microcontroller 106 and ensures increased comfort for a wearer of wearable item 101. In an embodiment, electrical circuit 103 and, consequently the moisture sensor provided therein, is provided on a flexible material layer having a first length. In the embodiment, wearable item 101 comprises a flexible material layer having a second length which, in this embodiment, may be considered to be the distance from the top of the waistband to the bottom of the gusset area. In particular, the flexible material onto which the moisture sensor and electrical circuit 103 is provided has a length which is larger than the second length of the wearable item. Specifically, the additional length of the flexible material layer supporting electrical circuit 103 allows for stretching of wearable item 101 and the flexible material layer of electrical circuit 103 without inducing damage from stretching to electrical circuit 103. In an embodiment, the first length is twice that of the second length. In an embodiment, microcontroller 106 comprises a wireless module which is configured to communicate with an electronic device such as, for example, a mobile telephone of the wearer or, for example, a medical professional. It is appreciated that microcontroller 106 may communicate with any suitable electronic device such as a laptop computer, tablet or desktop computer. In order to enable suitable connection of microcontroller 102 to electrical circuit 103, an apparatus for providing an electrical connection to the wearable item is provided herein. The example of Figure 1 illustrates a suitable wearable item which may comprise the present invention. It is appreciated however that, wearable items which utilise electrical circuitry and incorporate smart technology may also be utilised and, it is appreciated that electrical circuit 103 may be configured to perform alternative measurements beyond the detection of moisture. For example, the electrical connection and connectors described herein are also suitable in embodiments which incorporates heated wearable items or wearable items which provide monitoring of other medical data such as, for example, electromyography (measuring muscle activity), cardiography (measuring heart rate) or other medical data. It is further appreciated that substantially similar arrangements may also be utilised in non-wearable items such as in vehicle seats or other interior or exterior vehicle surfaces, for example, in the automotive industry, while also being appropriate for non-medical embodiments such as providing audiovisual technology to flexible wearable items. It is further anticipated that the invention described herein may be utilised in civil engineering structures including buildings, walls, floors and ceilings, and in applications involving electrical equipment, furniture, textiles, toys and skin monitoring for humans or animals. Figure 2 An apparatus for providing an electrical connection to a wearable item or other flexible material is shown in schematic cross-section in Figure 2. In the embodiment, apparatus 201 comprises a flexible material layer 202, a conductive material forming an electrical circuit 203 and a substantially rigid stiffening layer 204. In the embodiment, the conductive material forming an electrical circuit is formed as part of a conductive transfer 205. Conductive transfer 205 comprises electrical circuit 203 which is sandwiched between a first non-conductive encapsulating layer 206 and a second non-conductive encapsulating layer 207. Conductive transfer 205 further comprises an adhesive layer 208 which is configured to adhere conductive transfer 205 to flexible material layer 202. The embodiment of Figure 2 provides an example arrangement of a conductive transfer and it is further appreciated that alternative arrangements can be used. For example, in an alternative embodiment, more than one circuit layer separated by insulating or non-conductive layers is used. In this embodiment, the insulating layers may comprise a UV dielectric material. This may be particularly advantageous in applications where male connectors are formed with contact points present on both top and bottom sides of the connector. Electrical circuit 203 terminates to form a connection point 209 at an edge of flexible material layer 202. Rigid stiffening layer 204 is consequently configured to support flexible material layer 202 at connection point 209. In this way, flexible material layer 202 has free flexibility at end 210 while being supported rigidly at edge 211 consistent with connection point 209. Thus, when flexible material layer forms part of a wearable item, such as wearable item 101, the wearable item can be worn in comfort in a conventional manner while support remains provided at connection point 209 such that a suitable connector can be received by the flexible material layer and electrical circuit as will be described further herein. In an embodiment, an adhesive is included between flexible material layer 202 and rigid stiffening layer 204 in order to bond the two layers together and prevent separation. Figure 3 A schematic showing a method of manufacturing a wearable item comprising an electrical connection such as that described previously in respect of Figures 1 and 2 will now be described with respect to Figure 3. At step 301, a wearable item, garment, garment panel or other suitable surface is provided. The wearable item, garment or garment panel may be any suitable flexible material configured to be worn by a user and for which requires electrical functionality and the inclusion of an electrical circuit. While it is appreciated that the garment illustrated in Figure 1 is that of underwear, it is further anticipated that alternative embodiments, other wearable items such as jackets, T-shirts, shirts, trousers, shorts, or any other suitable wearable items comprising a flexible material may be utilised. In order to provide a suitable connection point, an optional step 302 may be utilised. For garments comprising relatively thin flexible materials, step 302 may not be required; however, due to the nature of the necessary connection point, in some embodiments an opening is cut into the flexible material layer of the wearable item. This enables, at step 303, a second material to be applied to the opening which is located at the connection point which is configured to receive an appropriate connector in use. In the embodiment, the second material comprises a thickness of between thirteen hundred and fifteen hundred microns (1300 to 1500 pm). In the embodiment, the second material comprises a plastics material and, in one embodiment, comprises thermoplastic polyurethane (TPU). In the embodiment, an adhesive layer is also included with the thermoplastic polyurethane (TPU). In a specific embodiment, two layers of TPU are included and applied to the opening in the flexible material. Once the second material is included to cover the opening and attached to the flexible material, at step 304 the flexible material and second material in combination are pressed and an application of heat and / or pressure is applied in a conventional heat press. This has the effect of removing any potential shrinkage in the flexible material of the wearable item and the additional second material such that, when the following steps of applying the conductive transfer are conducted, the material layers do not shrink in the process and, a smooth connection is provided between the flexible material of the garment and the conductive transfer. The process of pre-pressing the flexible material and second material further ensures that as any inherent shrinkage has been pre-removed from the materials, alignment is retained between the electrical circuit of the conductive transfer printed thereon, and the resultant connector to be attached. This particular step therefore should be conducted prior to application of the conductive transfer at step 305. At step 305 a suitable conductive transfer is obtained for transfer to the garment or wearable item at step 306. The conductive transfer in question may be any suitable conductive transfer which incorporates an electrical circuit in accordance with the requirements of the application in question and use of the finished wearable item. At step 307 a stiffening layer is located in the region of the connection point to enable support of the flexible material layer in use and when a connector is attached thereto. The stiffening layer can further be secured in place by means of a suitable adhesive or tape. Once the stiffening layer is in position following step 307, in an embodiment, the flexible material, which now incorporates a conductive transfer, may be folded around the substantially rigid stiffening layer at step 308. This particular embodiment is illustrated in Figures 4 to 6. This particular method adds an additional securing method to the flexible material and stiffening layer; however, it is appreciated that in alternative embodiments, such as that as depicted in Figure 7, this particular step of folding the material around the stiffening layer is not essential and is not present in other embodiments. Following the previous steps, the flexible material and conductive material, in combination with the substantially rigid stiffening layer should now be in a position to attach an appropriate connector which may allow for connection to a suitable microcontroller, electronic device or similar. In this way, the process at step 308 typically forms a male edge type connector which is connectable to a receptacle female connector attached to a printed circuit board. Thus, at step 309, a suitable receptacle connector is attached. Figure 4 An example apparatus for providing an electrical connection to a wearable item in which the apparatus comprises a connector attached thereto at a connection point is described with respect to Figure 4. The apparatus in Figure 4 is shown in schematic form and comprises a flexible material layer 401 and a conductive material forming an electrical circuit 402. In the embodiment, conductive material forming an electrical circuit 402 is printed on flexible material 401 by means of a conductive transfer 403 which has been suitably attached by means of an application of heat and pressure as described in the method shown in Figure 3. In the embodiment, the electrical circuit of the conductive material is encapsulated between first and second non-conductive encapsulating layers and an adhesive layer is included within the conductive transfer 403 in order to adhere conductive transfer 403 to flexible material layer 401. In the embodiment, flexible material 401 comprises a fabric material which is suitable for a wearable item or garment. In this embodiment, an opening 404 has been made into the fabric material of flexible material layer 401 and this has been replaced with a suitable second material in order to provide the required thickness for suitably receiving connector 405 which is shown attached thereto. Connector 405 is typically one which is commonly referred to as an edge connector. Such connectors are usually provided soldered to an edge of a printed circuit board. In the embodiment, the electrical circuit of conductive transfer 403 provides a plurality of termination points 406 at a connection point 407 which is configured to correspond to a connector's own contact points 408 when connector 405 is pressed onto flexible material layer 401. In this way, termination points 406 are configured to be inserted into a PCB receptacle edge connector, such as connector 405. In this way, connection point 407 comprises a first plurality of contact points while connector 408 comprises a second plurality of contact points. When connector 405 is attached to connection point 407, the first plurality of contact points and the second plurality of contact points are substantially aligned to enable any electrical data from the conductive material of electrical circuit 402 to be transmitted through connector 405 and to a further connected microcontroller or other electronic device. As the substantially rigid stiffening layer is included in the area of connection point 407, connector 405 can be securely attached to the terminal points of conductive transfer 403 and retained in position even as a wearer of the wearable item moves around while wearing the wearable item. Figure 5 An example embodiment of an electrical circuit printed onto a flexible material layer in accordance with the invention will now be described with respect to Figures 5 and 6. Figure 5 illustrates the apparatus 501 in plan view. In the embodiment, apparatus 501 comprises a flexible material layer 502 and a conductive material forming an electrical circuit 503. In the embodiment, the conductive material forming an electrical circuit is printed on flexible material layer 502 and this may be achieved by means of a conductive transfer which is subsequently applied to the flexible material layer during manufacture. It is appreciated that, in some embodiments, the conductive material from an electrical circuit may be directly printed onto the flexible material layer 502 to form a similar arrangement. It is further appreciated that, in this case, an adhesive layer may not be included in the apparatus. Apparatus 501 further includes a connection point 504. In this embodiment, electrical circuit 503 forms connection point 504 at eight points along a fold axis 505. Fold axis 505 represents the embodiment in which the flexible material layer is folded around the substantially rigid stiffening layer to form connection point 504 which is suitable for receiving a connector. Thus, it is appreciated in this case that a first part 506 of electrical circuit 503 may be considered as being formed on an upper layer of the flexible material layer while a second part 507 of the electrical circuit 503 may be considered as being formed on a lower layer of the flexible material layer 502. This is shown further with respect to Figure 6. Figure 6 A schematic cross-section of apparatus 501 is shown in Figure 6 in which the apparatus has been folded around the substantially rigid stiffening layer 601. In the embodiment, flexible material layer 502 may be considered to comprise an upper fabric layer 602 and a lower fabric layer 603. As shown, flexible material layer 502 has been folded about fold axis 505 which, in this arrangement, extends into the page, such that electrical circuit 503 includes first part 506 positioned on upper fabric layer 602 with second part 507 positioned on lower fabric layer 603. This consequently allows for the electrical circuit to be accessed on both sides of the flexible material layer in use. In the embodiment, the substantially rigid stiffening layer 601 is located between upper fabric layer 602 and lower fabric layer 603. In the embodiment, the conductive material forming an electrical circuit 503 is provided by a conductive transfer 604 which comprises an adhesive layer 605 which is configured to attach the conductive transfer 604 to the flexible material layer 502. Conductive transfer 604 further comprises a first non-conductive encapsulating layer 606, a second non-conductive encapsulating layer 607 and a conductive layer 608 which provides the conductive material forming an electrical circuit 503. It is appreciated that, in alternative embodiments, a conductive transfer is utilised which comprises an adhesive layer, a first non-conductive encapsulating layer and a second non-conductive encapsulating layer and a plurality of conductive layers each separated by a non-conductive or insulating layer. In this embodiment, each of the plurality of conductive layers provide additional electrical circuits or combined to provide a more complex electrical circuit across multiple layers. Figure 7 A further embodiment of an apparatus for providing an electrical connection to a wearable item is shown in plan view in Figure 7. In the embodiment, apparatus 701 differs from apparatus 501 in that it is formed with a method that does not involve folding the flexible material around the rigid stiffening layer and, is instead comprised of a flexible material layer 702 onto which the conductive material forming an electrical circuit 703 is printed thereon. In this embodiment, the substantially rigid stiffening layer is positioned at connection point 704 of electrical circuit 703 and is consequently configured to support flexible material layer 702 at connection point 704. Thus, the rigid stiffening layer is positioned at the edge 705 of flexible material 702 and extends beneath electrical circuit 703 towards connection point 704 as necessary. Figure 8 Figures 8 to 10 show an example embodiment of the apparatus for providing an electrical connection which further comprises a flexible securing mechanism configured to secure a connector at the connection point. A schematic cross-sectional view of such apparatus is shown in Figure 8. Apparatus 801 comprises a flexible material 803 which is printed onto the flexible material layer 802. In an embodiment, electrical circuit 803 is provided in the form of a conductive transfer comprising a plurality of layers. As with previous embodiments, it is anticipated that the conductive transfer may comprise an adhesive layer, a first non-conductive encapsulating layer, a conductive layer which provides the electrical circuit, and a second non-conductive encapsulating layer. The conductive layer is positioned between the first and second non-conductive encapsulating layers. In the embodiment, a substantially rigid stiffening layer 804 is configured to support the flexible material layer 802 and electrical circuit 803 at a connection point 805 located at an edge 806 of flexible material 802. In the embodiment, rigid stiffening layer 804 comprises an extending portion providing a flexible securing mechanism 807 which is configured to secure a connector to connection point 805. Figure 9 A perspective view of apparatus 801 is shown in Figure 9. Electrical circuit 803 extends across flexible material 802 to connection point 805 which comprises a plurality of conductive terminals or contract points which are configured to connect to a suitable connector having corresponding terminals or contact points. In the embodiment, the substantially rigid stiffening layer 804 extends underneath the flexible material layer 802, electrical circuit 803 and connection point 805. In the embodiment, rigid stiffening layer 804 comprises a flexible securing mechanism 807 which extends away from connection point 805 to provide a flexible extending portion 901. The rigid stiffening layer 804 further comprises an aperture 902 positioned between flexible extending portion 901 and the edge of the rigid stiffening layer 804 at the connection point. Aperture 902 is appropriately sized to enable receipt of a corresponding connector such that aperture 902 is large enough for a connector to be placed therein and positioned onto and over the connection point and contact points 805. In the embodiment, rigid stiffening layer 804 further comprises a locator tab 903 which is configured to ensure accurate location of a connector once the connector is positioned in contact with the contact points 805 of electrical circuit 803. Figures 10A and 10B Apparatus 801 is further depicted in Figure 10 with a suitable connector 1001 attached thereto. In the embodiment, connector 1001 can be pushed onto the contact points of electrical circuit 803 such that the plurality of contact points corresponds to a corresponding plurality of contact points on connector 1001. Figure 10A shows a perspective view of this arrangement whereby connector 1001 is positioned in aperture 902 and is consequently surrounded by the extending portion 901 of rigid stiffening layer 804. In this way, a connection can be made between connector 1001 and the electrical circuit 803 at connection point 805 on the edge of flexible material layer 802. Apparatus 801 is shown further in a cross-sectional side schematic view in which connector 1001 is positioned to encompass the electrical circuit 803, flexible material layer 802 and the supporting parts of the rigid stiffening layer 804. Extending portion 901 of flexible securing mechanism 807 is moved around connector 1001 so as to hold connector 1001 against electric circuit 803. In this way, the flexible securing mechanism 807 secures connector 1001 by pushing connector 1001 towards the edge 806 of the flexible material layer and electrical circuit 803. In the embodiment, the rigid stiffening layer 804 comprises a suitable flexible material. In an embodiment, the rigid stiffening layer comprises a plastics material. In one embodiment this material is polyimide and, in a specific embodiment this comprises a glass-reinforced epoxy laminated composite material, commonly provided under the designation FR4. In an alternative embodiment, the rigid stiffening layer comprises thermoplastic polyurethane (TPU). In an embodiment, the thickness of the rigid stiffening layer is between zero point one and two point five millimetres (0.1 mm and 2.5 mm) thick. Figure 11 In cases where the embodiment of Figures 8 to 10 is not appropriate, alternative embodiments may be necessary. An example alternative embodiment will now be described with respect Figures 11 and 12. A schematic cross-sectional view is shown of an example apparatus 1101. In this embodiment, apparatus 1101 comprises a housing 1102 configured to house the connection point 1103 and part of the flexible material layer 1104 in addition to the rigid stiffening layer supporting the flexible material at the connection point. In the embodiment, the rigid stiffening layer further comprises a locator tab 1105 which is configured to ensure accurate location of a connector once fitted. This ensures that any connector is positioned in the correct way and does not require any additional expertise or understanding from a user to fit. In this embodiment, apparatus 1101 further comprises a locking mechanism comprising a lever mechanism 1106. The lever mechanism will be described further with respect to Figure 12. Figures 12A and 12B Figures 12A and 12B show lever mechanism 1106 of apparatus 1101 in cross-sectional schematic form with Figure 12A showing lever mechanism 1106 in an unlocked position and Figure 12B showing lever mechanism 1106 in a locked position. In the embodiment, housing 1102 houses electrical circuit 1103 which is configured to receive an appropriate connector which can be positioned in aperture 1201. Lever mechanism 1106 comprises an actuator 1202 and a lever portion 1203. When actuator 1202 receives a force in the direction of arrow 1204, lever portion 1203 is configured to pivot from the position in Figure 12A to the position in Figure 12B about pivot point 1205. Consequently, when a connector is in position in aperture 1201 this can appropriately be held in position and in secure contact with the electrical circuit 1103. If the connector is required to be removed, actuator 1202 may be pushed in the opposite direction to arrow 1204 so as to release the lever portion 1203 such that lever portion 1203 pivots back to the position shown in Figure 12A. Figure 13 A further embodiment for providing a means of connection to the electrical circuit will now be described with respect to Figures 13 to 16. In the embodiment, an apparatus 1301 comprises a flexible material layer and a conductive material forming an electrical circuit printed on the flexible material. The apparatus further comprises a substantially rigid stiffening layer. In this embodiment, the apparatus further comprises a housing 1302 which houses the connection point and part of the flexible material layer and rigid stiffening layer located at the connection point. In this way, the flexible material layer 1303 may form part of a wearable item or garment which therefore includes the housing 1302 attached thereto. In the illustrated exploded view of Figure 13, housing 1302 comprises a magnetic connector which is a magnetic spring-loaded connector and which is configured for magnetic attachment to a corresponding plug 1304. Plug 1304 comprises a magnetic connection and a plurality of cylindrical contacts on a connector surface 1305. In the embodiment, plug 1304 comprises a universal serial bus (USB) 1306. In the embodiment, it is appreciated that the universal serial bus is aligned with current specifications for USB-A or USB-C connectors readily available. Figure 14 In the embodiment, housing 1302 comprises a plurality of spring-loaded contacts 1401 configured to transmit and receive data and power from the electrical circuit contained within the housing. In the embodiment, the spring-loaded contacts 1401 are made from a metallic material such as gold. It is appreciated that other metallic materials may be utilised for this purpose. In the embodiment, the magnetic housing comprises a cylindrical housing. However, it is appreciated that while cylindrical housing may be chosen to satisfy conventional USB connectors, in alternative embodiments, alternative shaped housing may be utilised. Figure 15 In the embodiment shown previously in Figures 13 and 14, a plan view of the connection point arrangement on the electrical circuit positioned within housing 1302 is shown in plan view in Figure 15. In the embodiment, connection point 1501 comprises a plurality of contacts 1502 which are consistent with conventional universal serial bus (USB) connections to enable efficient connection via the magnetic spring-loaded connector described in Figures 13 and 14. In addition, the flexible material layer comprises a plurality of apertures 1503 which are configured to receive part of a universal serial bus connector as necessary and to ensure alignment between the connection point of the apparatus 1301 and the corresponding USB connector. Figure 16 A further view of housing 1302 is shown in Figure 16 in cross-sectional schematic view in which flexible material layer 1303 extends from housing 1302 and in which electrical circuit 1501 remains in contact with housing 1302 to provide connection on face 1307 with the corresponding magnetic connector 1304 In addition, apparatus 1301 comprises a rigid stiffening layer 1601 which is positioned underneath the flexible material layer within housing 1302. Figure 17 An alternative embodiment for providing a means of connection to the electrical circuit is now described with respect to Figures 17 and 18. In the embodiment of Figure 17 and 18, this may be particularly useful for universal serial bus type connections, in particular those for USB-C. The illustrated example in Figure 17 shows an exploded schematic side view of a flexible material layer 1701 onto which a conductive material forming an electrical circuit 1702 is printed thereon. This arrangement may be substantially similar to any described previously. In addition, the embodiment includes a substantially rigid stiffening layer 1703 onto which the flexible material 1701 and electrical circuit 1702 may be attached thereto. A connector 1704 is configured to attach at the connection point 1705 of electrical circuit 1702 Connector 1704 comprises a housing 1706 and a plurality of protrusions 1707 which extend from housing 1706. In the embodiment, connector 1704 is consistent with available USB-C housing in which contact points are present on a lower surface 1708 of housing 1704. Figure 18 In the embodiment, as shown in the exploded perspective view of Figure 18, electrical circuit 1705 comprises a plurality of conductive tracks, such as track 1801, which are configured to contact with the contact points on lower surface 1708. In order to ensure appropriate alignment, rigid stiffening layer 1703 comprises a plurality of slots 1802 which correspond to the protuberances 1707 such that, when housing 1704 is positioned over electrical circuit 1705 and conductive tracks 1801, flexible material layer 1701 and rigid stiffening layer 1703, conductive tracks 1801 are appropriately aligned with the contact points on lower surface 1708. Slots 1802 further ensure that housing 1704 remains in place when in use by ensuring limited movement due to the protrusions 1707.
Claims
The invention claimed is:
1. Apparatus for providing an electrical connection, comprising:a flexible material layer;a conductive material forming an electrical circuit printed on said flexible material layer;a substantially rigid stiffening layer; whereinsaid electrical circuit forms a connection point at an edge of said flexible material layer and said substantially rigid stiffening layer is configured to support said flexible material layer at said connection point.
2. The apparatus of claim 1, wherein said flexible material layer comprises a fabric material.
3. The apparatus of claim 1 or claim 2, wherein said flexible material layer comprises an upper fabric layer and a lower fabric layer; andsaid substantially rigid stiffening layer is located between said upper fabric layer and said lower fabric layer.
4. The apparatus of any one of claims 1 to 3, wherein said conductive material forming an electrical circuit is provided by a conductive transfer comprising an adhesive layer, a first non-conductive encapsulating layer, a conductive layer and a second non-conductive encapsulating layer.
5. The apparatus of any one of claims 1 to 3, wherein said conductive material forming an electrical circuit is provided by a conductive transfer comprising an adhesive layer, a first non-conductive encapsulating layer and a second non-conductive encapsulating layer; and further comprising:a plurality of conductive layers each separated by a non-conductivelayer.
6. The apparatus of any preceding claim, wherein said flexible material layer comprises a barrier layer, an absorbent layer and a permeable layer.
7. The apparatus of any preceding claim, wherein said conductive material forming an electrical circuit is configured to provide a moisture sensor.
8. The apparatus of any preceding claim, wherein said flexible material layer comprises a fabric material comprising an opening, said opening comprising a second material located at said connection point.
9. The apparatus of any preceding claim, further comprising a connector attached thereto at said connection point.
10. The apparatus of claim 9, wherein said connection point comprises a first plurality of contact points and said connector comprises a second plurality of contact points; said first plurality of contact points and said second plurality of contact points being substantially aligned when said connector is attached to said connection point.
11. The apparatus of any preceding claim, wherein said rigid stiffening layer comprises a locator tab configured to ensure accurate location of a connector.
12. The apparatus of any preceding claim, further comprising a housing configured to house said connection point and part of said flexible material layer and said substantially rigid stiffening layer at said connection point.
13. The apparatus of claim 12, wherein said housing comprises a locking mechanism comprising a lever mechanism.
14. The apparatus of any preceding claim, further comprising a flexible securing mechanism configured to secure a connector to said connection point.
15. The apparatus of any preceding claim, further comprising a housing comprising a magnetic spring-loaded connector.
16. The apparatus of claim 15, wherein said magnetic spring-loaded connector is configured to receive a corresponding magnetic connector comprising a universal serial bus.
17. A wearable item comprising the apparatus of any preceding claim.
18. The wearable item of claim 17, wherein said wearable item comprises a microcontroller.
19. The wearable item of claim 18, wherein said microcontroller is located into a pocket of said wearable item.
20. The wearable item of any one of claims 17 to 19, wherein said wearable item comprises a moisture sensor.
21. The wearable item of claim 20, wherein said moisture sensor is provided on a flexible material layer having a first length, and said wearable item comprises a flexible material layer having a second length; said first length is larger than said second length.
22. A method of manufacturing an apparatus comprising an electrical connection, comprising the steps of:pressing a flexible material layer with an application of heat;printing a conductive material forming an electrical circuit onto a transfer 5 substrate;transferring said conductive material forming an electrical circuit from said transfer substrate to said flexible material layer by means of a further application of heat;forming a connection point at an edge of said flexible material layer with10 said electrical circuit; andlocating a substantially rigid stiffening layer to support said flexible material layer at said connection point.
23. The method of claim 22, further comprising the steps of:15 cutting an opening in said flexible material layer; andproviding a second material to said opening and locating said second material at said connection point.
Citation Information
Patent Citations
Stretchable cable and stretchable circuit board
US20180070446A1
Stretchable circuit board and method for manufacturing stretchable circuit board
US20180092206A1
Sanitary product with integrated sensor, fabrication plan therefor and method thereof
US20210077309A1
Sanitary product with integrated sensor, semi-manufactured sanitary product, fabrication plan therefor, and method for producing thereof
US20210077310A1
Soft sensor-embedded glove and method for manufacturing same
US20210153578A1