Electronic device-textile interconnection method and system

Abstract

The present invention provides an apparatus and method for securely attaching an electronic module to a textile. [Solution] The overall mechanical assembly includes a main electronic device 22, which includes a main PCB 28, a battery 70, and other electronic components; a lower enclosure 24, which holds a connector PCB 26; a module dock 14; an upper textile PCB 28, which is located above a textile band 34 and below a textile pocket; and a textile and laminated pad 32 located below the textile band 34. The present invention is physically embodied by an electronic module comprising at least one printed circuit board (PCB) having at least one conductive circuit and at least one electronic component; metal rivets, grommets or eyelets for mechanical and electrical connections; and a textile substrate having at least one conductive circuit.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority from U.S. Provisional Patent Application No. 62 / 614,380, filed on January 6, 2018, the entire content of which is incorporated herein by reference.

[0002] The present invention generally relates to smart textiles. More specifically, the present invention relates to methods and systems for connecting electronic components to conductive fabrics.

Background Art

[0003] Smart textiles are fabric - based systems of materials and structures that sense and respond to environmental conditions or stimuli, such as those from mechanical, thermal, chemical, electrical, magnetic or other sources. Smart textiles can react or adapt to external stimuli or changing environmental conditions. The stimuli can include changes in temperature, moisture, pH, chemical sources, electric or magnetic fields, mechanical stress or strain.

[0004] Advanced smart textiles can have embedded computing, digital components, electronic devices, energy supply, and sensors. The basic components of smart textiles include sensors, actuators, data transmission, and power. When difficult functionality, size, cost, reliability, comfort, and aesthetic / requirements are considered, the requirement to seamlessly integrate electronic components into fabric manufacturing is not met. Further, the electrical connection between electronic components, such as power and computing components (e.g., processors, memories, etc.), and conductive circuits in the fabric (e.g., conductive fibers of the fabric substrate, wires, etc.) requires a connection that is adaptable and / or reliable to the fabric.

[0005] Moreover, fabric manufacturing and electronic component manufacturing use highly disparate assembly equipment, materials, and processes, and employ significantly different manufacturing infrastructures.

[0006] Therefore, there is an urgent need for materials and manufacturing methods that can easily integrate the interconnection of electronic devices or electronic device modules into a fabric-based substrate. [Overview of the Initiative] [Means for solving the problem]

[0007] The present invention provides a docking method and system that eliminates or mitigates at least one of the drawbacks presented above.

[0008] A first embodiment provided is a docking station assembly that provides a releaseable and secure connection between an electronic controller device and one or more conductive paths of a textile substrate, the module docking station having a body fixedly connected to a substrate assembly mounted on a textile substrate, the body exposing an electrical docking connector configured to mate with an electrical controller connector of the electronic controller device, and a substrate assembly, a first substrate, placed on one surface of a textile substrate such that one or more first electrical connection points of the first substrate are aligned with one or more conductive paths, the first substrate having an electrical controller connector mounted thereon A docking station assembly comprising: a substrate assembly having a first substrate having a connector and being electrically connected to one or more first electrical connection points by one or more substrate conductive paths; a second substrate having one or more second electrical connection points aligned with one or more first electrical connection points, and a fastener having one or more fasteners, each fastener fixing one or more second electrical connection points to one or more first electrical connection points, thereby firmly fixing the fabric substrate between the first substrate and the second substrate; wherein one or more first electrical connection points are in electrical contact with one or more adjacent conductive paths.

[0009] The present invention provides an apparatus and method for securely attaching an electronic module to a textile. The electronic module comprises a printed circuit board (PCB) having at least one conductive circuit and at least one electronic component, mechanical and electrical connections to a textile substrate, and a textile substrate having at least one conductive circuit.

[0010] Optionally, a rigid case covering the PCB and electronic components on the PCB, and optionally, preferably, pockets for holding the rigid case, woven directly into a woven fabric base. Finally, in a third optional embodiment, a magnetic system to prevent the module from moving within the pockets.

[0011] The accompanying drawings, incorporated herein and forming part of the specification, illustrate the present invention and, together with the description, further illustrate the principles of the present invention, enabling those skilled in the art to manufacture and use the present invention. [Brief explanation of the drawing]

[0012] [Figure 1] This shows an enlarged (or exploded) view of the entire assembly. [Figure 2] Figure 1 shows a perspective view of the circuit board components of the overall assembly. [Figure 3] Figure 1 shows a perspective view of the overall assembly and further substrate components. [Figure 4] Figure 2 shows a perspective view of the substrate component in relation to the woven fabric base material in Figure 1. [Figure 5] Figure 1 shows a perspective view of the dock station body in relation to the woven fabric base material shown in Figure 1. [Figure 6] Figure 1 shows an example of the electronic components of the controller device. [Figure 7] Figure 1 provides an internal diagram of the controller device. [Figure 8] Figure 1 provides an internal diagram of the controller device. [Figure 9] Figure 3 provides a diagram of the substrate component in relation to the woven fabric base material shown in Figure 1. [Figure 10] Figure 3 provides a diagram of the substrate component in relation to the woven fabric base material shown in Figure 1. [Figure 11] Provide a view of the substrate component of FIG. 3 in relation to the fabric substrate of FIG. 1. [Figure 12] Provide views of the controller device of FIG. 1 in both the assembled and unassembled states. [Figure 13] Provide views of the controller device of FIG. 1 in both the assembled and unassembled states. [Figure 14] Provide views of the controller device of FIG. 1 in both the assembled and unassembled states. [Figure 15] Show a cross-sectional view of the entire assembly of FIG. 1 after assembly. [Figure 16] An exemplary view of the fabric substrate of FIG. 1 including conductive paths. [Figure 17] An exemplary flowchart of the assembly method of the entire assembly of FIG. 1. [Figure 18] An exemplary flowchart of the assembly method of the entire assembly of FIG. 1. [Figure 19] An exemplary flowchart of the assembly method of the entire assembly of FIG. 1. [Figure 20] An exemplary flowchart of the assembly method of the entire assembly of FIG. 1. [Figure 21] An exemplary flowchart of the assembly method of the entire assembly of FIG. 1.

Embodiments for Carrying out the Invention

[0013] In the following detailed description of the invention of the exemplary embodiments of the present invention, reference is made to the accompanying drawings, in which like numerals represent like elements, which form a part of this specification, and in which are shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, but other embodiments may be utilized and logical, mechanical, electrical, and other changes may be made without departing from the scope of the invention. Accordingly, the following detailed description is not to be construed in a limiting sense, and the scope of the present invention is defined only by the appended "claims".

[0014] In the following description, specific details are set forth in order to provide a thorough understanding of the invention. It will be understood, however, that the invention may be practiced without these specific details. In other instances, well-known structures and techniques have not been shown in detail in order not to obscure the invention. Referring to the drawings, various major elements constituting the apparatus of the invention can be seen.

[0015] Referring to Figure 1, the diagram shows an enlarged (or exploded) view of an entire assembly 10 of a controller device 12 (e.g., an electronic module) electrically connected to a conductive path 80 (see Figure 16) of a textile substrate 34 (e.g., in the form of a patch, band, shirt, pants, socks, underwear, blanket, hat, gloves, shoes, etc.) via a module docking station 14. As such, as will be described later, the module docking station 14 (see Figure 5) may comprise a docking housing 50 having a body 14a including an opening 52, which provides access between an electrical docking connector 54 (see Figure 4) coupled to the conductive path 80 and an electrical controller connector 26 (see Figure 1) connected to the electronics 22 of the controller device 12. The module docking station 14 may also have one or more clips 55 (as an example of a mechanism that can be releasably fixed for mechanical coupling with the housings 18, 24 of the controller device 12). It is clear that the mating electrical connection between the electrical dock connector 54 and the electrical controller connector 26 can also be fixed in a detachable manner, thus facilitating repeated mounting and detachment of the controller device 12 to the module dock station 14, both mechanically and electrically.

[0016] Periodic removal of the controller device 12 may be advantageous for recharging the power supply 70 (see Figure 1) of the controller device 12, replacing / substituting the controller device 12 (including the electronic components 22), and / or temporarily removing the controller device 12 for the purpose of washing / cleaning the fabric substrate 34 (for example, when washing a garment in which the fabric substrate 34 is integrally incorporated as part of the overall garment structure).

[0017] Referring again to Figure 1, the controller device 12 has housings 18, 24 (e.g., an upper enclosure and a lower enclosure) that provide a moisture-resistant housing for the enclosed electronic equipment 22. Referring, for example to Figure 6, the electronic equipment 22 may include a memory 72 and a power supply 70 (e.g., a rechargeable battery) that supplies power to the computer processor 74 so that the computer processor can execute instructions stored in the memory (e.g., ROM, RAM, etc.). Electrical connections between the electronic equipment 22 may be by conductive paths 76 (shown conceptually) on a printed circuit board (PCB) or other electronic equipment board 78. The conductive paths 76 may be electrically connected to an electrical controller connector 26 (e.g., a socket connector, e.g., an 8-socket connector) so that the electrical controller connector 26 can be considered as an integral part within the housings 18, 24 (see Figure 7). As such, the electrical controller connector 26 can be considered as part of the controller device 12.

[0018] The lower enclosure 24 of the housing may include an opening 79a, which receives the corresponding pins 79b attached to the body 54a of an electrical dock connector 54 (e.g., an 8-pin connector). It is also assumed that the electrical dock connector 54 may be a socket connector, and the electrical controller connector 26 may be a pin connector 26 configured to mate with the socket connector 54. The electrical connectors 26, 54 may have mating electrical connections other than pin / socket type (e.g., magnetic) as needed, and it is also recognized that the electrical connectors 26, 54 may be of a type that can be detachably fixed. As shown in Figure 8, the electrical controller connector 26 may be sealed to the inner surface 84 (of the housing 18, 24 when assembled) via a seal 82 (e.g., adhesive). The seal 82 may be used to prevent moisture or other foreign matter from entering the interior 86 (see Figure 7) through the opening 79a (see Figure 7).

[0019] Referring again to Figure 1, the overall assembly 10 also includes a first substrate 28 and a second substrate 30 for mounting on both sides of the woven substrate 34. For example, the first substrate 28 can be a PCB. As shown in Figure 2, the first substrate 28 has an electrical dock connector 54 mounted thereon, and each of the one or more electrical connectors 79b (e.g., pins, sockets, etc.) of the electrical dock connector 54 has a conductive path 43 connecting to one or more corresponding electrical connection points 42 mounted on the first substrate 28. The one or more electrical connection points 42 can be distributed with respect to the surface 28a of the first substrate 28, and it is recognized that each of the one or more electrical connection points 42 corresponds to (e.g., is at a relative distance from each other) a conductive path 80 (see Figure 16) located on / inside the woven substrate 34. The first substrate 28 may also have one or more electrical components 25, which are mounted thereon and thus electrically connected to the electronic equipment 22 via mating connectors 26, 54 (pins / sockets) through corresponding conductive paths 43. As shown, the first substrate 28 may have a plurality of openings 28b that correspond in spatial distribution to the holes 34b of the woven substrate 34 (see Figure 4). The openings 28b also correspond in spatial distribution to a series of openings 30b on the surface 30a of the second substrate 30 (e.g., PCB). In the assembly of the overall assembly 10, the first substrate 28 can be attached to the corresponding surface 34a of the woven substrate 34 by adhesive layer A. In the assembly of the overall assembly 10, the second substrate 30 can be attached to the corresponding opposing surface 34a of the woven substrate 34 by similar adhesive layer A.

[0020] Referring to Figure 3, the second substrate 30 is mounted on the surface 34a of the fabric substrate 34 opposite to the surface used to mount the first substrate 28, so that the fabric substrate 34 is securely fixed between the substrates 28 and 30, as will be further described below. The second substrate 30 also has connection points 42a corresponding to electrical connection points 42, and corresponding mechanical fasteners 29 (e.g., rivets - see Figure 2) can be used to mechanically fasten the first substrate 28 to the second substrate 30, so that the fabric substrate 34 can be fixedly sandwiched / mounted between them.

[0021] Referring again to Figure 4, any pocket 35 of the woven substrate 34 can be used to house the first substrate 28, if necessary. As can be seen from Figure 5, any pocket 35 can also be used to house the module docking station 14 when fixed to the first substrate 28 (more on this below). Referring again to Figure 1, the second substrate 30 can be covered with any lining material 32 (e.g., woven fabric, plastic, pad, laminate, etc.) that can provide wearer comfort to the woven substrate 34 (e.g., incorporated into clothing) when the lining material 32 is in contact with the wearer's skin. The entire assembly 10 may also include a light pipe 16 that indicates the functional status of the electronics 22 via one or more visual indicators (e.g., LEDs), as well as magnets 20 positioned inside the housings 18, 24. In summary, once assembled, the housings 18, 24 of the controller device 12 can be mechanically and electrically removably fixed to the module docking station 14. The module docking station 14 is fixedly attached to the first substrate 28, and is fixedly attached to the textile substrate 34 via mechanical (e.g., fasteners) / chemical (e.g., adhesive) connections between the first substrate 28 and the second substrate 30 when positioned on the opposing surfaces 34a of the textile substrate 34.

[0022] Referring again to Figures 2, 3, and 4, the openings 28b, 30b and hole 34b can be used to fasten the module docking station 14 to the substrates 28, 30 and thus securely fasten the module docking station 14 to the fabric substrate 34. For example, one method of fastening the module docking station 14 to the substrates 28, 30 is to use a crimping method (see Figures 5, 9, and 15), which is the process of connecting two parts (module docking station 14 and substrates 28, 30) by creating an interference fit of fasteners 90 between the two parts (module docking station 14 and substrates 28, 30). One workpiece 28, 30 has holes 28b, 30b in it, and the other (module docking station 14) has bosses 90 that fit into the holes 28b, 30b. It is recognized that one of the workpieces 28, 30 may have holes 28b, 30b, respectively, while the other piece (module docking station 14) may have fasteners 90 attached to the corresponding surfaces 28a, 30a. The fasteners 90 (e.g., bosses) may be made very slightly smaller so as to form a slip fit with the holes 28b, 30b. A staking punch may then be used to expand the boss 90 radially and compress it axially so as to form an interference fit between the workpieces (module docking station 14 and substrates 28, 30). This interference fit forms a permanent bond / connection between the two pieces so as to firmly fix the intervening fabric substrate 34 between the two substrates 28, 30, which is to be fixed to the module docking station 14 via riveting. The riveting process may also be referred to as thermoplastic staking, also known as heat staking, which is the same process except that heat is used to deform the plastic boss 90 instead of cold forming. A plastic stud 90 protruding from one component fits into a hole in the second component. The stud 90 is then deformed by the softening of the plastic to form a head that mechanically locks the two components (module docking station 14 and substrates 28, 30) together.Unlike welding, riveting has the ability to join similar or dissimilar plastics, as well as plastics to other materials (e.g., metals, PCBs), and is advantageous over other mechanical joining methods in that it reduces the need for consumables such as rivets and screws.

[0023] Referring to Figures 10 and 11, an example of a backing 32 for covering the second substrate 30 after it has been fixed to the first substrate 28 is shown. Referring to Figures 12, 13, and 14, the housings 18 and 24 are shown in their unassembled and assembled states, and the interior 86 with the mounted light pipe 16 and magnet 20 is shown as an example. Referring to Figure 16, a cross-sectional view of the entire assembly 10 is shown, including an optional piezo sensor mounted between the first substrate 28 and the body 14a of the module dock station 14.

[0024] Referring to Figure 16, for illustrative purposes only, an example of a woven fabric substrate 34 having a conductive path 80 is shown along with the position of the electrical connector position 42 (and / or fastener 29) in Figure 2 in ghost view. It is recognized that the electrical connection between the electrical connector position 42 and the conductive path 80 is fixed when the electrical connector position 42 (of the first substrate 28) is in contact with the conductive path 80, and that this is maintained by 1) a fixed connection between substrates 28, 30 (e.g., via a fastener 90), thus sandwiching the woven fabric substrate 34 between them and biasing the electrical connector position 42 and the conductive path 80 to be in physical contact with each other, and / or 2) a connection between substrates 28, 30 (e.g., a conductive fastener such as a metal rivet, pin, etc.) via a fastener 29 (e.g., a conductive fastener such as a metal rivet, pin, etc.) when the fastener 29 is in physical contact with the electrical path 80 and the electrical connector position 42. The substrates 28 and 30 can be made of flexible or rigid material, as needed, insofar as the material holds the interconnection between positions 42 by the fasteners 29.

[0025] For example, current to the electronic device 22 follows a conductive path from a) conductive path 76 to b) electrical controller connector 26 to c) electrical dock connector 54 to d) conductive path 43 connecting each of the one or more electrical connectors 79b (e.g., pins, sockets, etc.) of the electrical dock connector 54 to e) corresponding electrical connection position 42 to finally f) conductive path located adjacent to and electrically coupled to the conductive path 80 of the textile base material 34 (e.g., via fasteners 29). Similarly, current from the conductive path 80 of the textile base material 34 follows a conductive path from a) conductive path 43 connecting each of the one or more electrical connectors 79b (e.g., pins, sockets, etc.) of the electrical dock connector 54 to d) electrical dock connector 54 to e) electrical controller connector 26 to f) conductive path 76 connected to the electronic device 22 to a) conductive path 76 located adjacent to and electrically coupled to the conductive path 80 of the textile base material 34 (e.g., via fasteners 29) to b) corresponding electrical connection position 42 to c) conductive path 43 connecting each of the one or more electrical connectors 79b (e.g., pins, sockets, etc.) of the electrical dock connector 54 to d) electrical dock connector 54 to e) electrical controller connector 26.

[0026] In manufacturing the overall assembly 10, the following exemplary manufacturing steps can be performed. Figure 17 shows an exemplary process 102 for manufacturing the woven substrate 34, including conductive paths 80 (e.g., circuits containing conductive wires / fibers to which mounted sensors / actuators are applied or otherwise woven into the fibers of the woven substrate 34). Figure 18 shows an exemplary method step 104 for manufacturing a sandwich of two substrates 28, 30 having the woven substrate 34. Referring to Figure 19, a method 106 is shown for fixing the module docking station 14 to a first substrate 28 located beneath and adjacent to the module docking station 14 (e.g., mechanically). Furthermore, the backing 32 is fixed to a second substrate 30 located beneath and adjacent to the backing 32 (e.g., with adhesive). Figure 20 shows an example 108 of manufacturing an electrical controller connector 26 to the housings 18, 24 of the controller device 12. Figure 21 shows a manufacturing method 110 for the main controller device 12, which includes mounting components 16, 20, and 22 inside the housings 18 and 24 and sealing the housings 18 and 24.

[0027] As shown above, the overall assembly 10 included a controller device 12, a module docking station 14 fixedly connected to substrates 28 and 30, and substrates 28 and 30 fixedly connected to a woven fabric substrate 34 (having multiple conductive paths 80). In this manner, once assembled, the controller device 12 is mechanically and electrically detachably fixed to the module docking station 14 to enable electrical communication between the electronic equipment 22 of the controller device 12 and the conductive paths 80 of the woven fabric substrate 34.

[0028] Accordingly, simply by example, (a) light pipe 16, (b) upper enclosure 18, (b) magnet 20, (c) main electronic equipment 22 which may include (d) main PCB 28, (e) battery 70 and (f) other electronic components 72, 74, 76, (g) lower enclosure 24 which (h) holds connector PCB 26, (i) module dock 14, (j) upper textile PCB 28 which (j) is located above textile band 34 and (k) is located below textile pocket 35, (l) lower textile PCB 30, and (m) textile and laminated pad 32 located below textile band 34.

[0029] Furthermore, the embodiments include apparatus and methods for providing a reliable interconnection between the electronic device 12 and the smart textile 34. The embodiments also facilitate the secure mechanical fastening of the electronic device 12 to the smart textile 34 while maintaining a robust electrical connection to the conductive circuit 80 of the smart textile 34, thereby ensuring the ability of the smart textile 34 or the electronic device 12 to withstand mechanical shocks, torsions, stretches, and other stresses that may be subjected to.

[0030] In some embodiments, the woven band 34 or woven base material 34 does not need to include electrical or electronic components. In some embodiments, the woven base material 34 may include only conductive circuits 80, such as conductive yarns, fibers, or printed electronic circuits. In other embodiments, the woven base material 34 may include fully functional and active electronic components, sensors, circuits, etc.

[0031] For the purpose of a wearable smart textile 34 worn on the body, the direction below the woven band 34 is interpreted as being closer to the body, and the direction above the woven band 34 is further away from the body. The woven pocket 35 is preferably a structure that rises on the woven band 34 and is manufactured by weaving into the woven structure of the woven band 34.

[0032] In some embodiments, the woven substrate 34 (also referred to as the woven band 34) incorporates health management sensors in the form of ECG sensor pads, respiratory monitoring sensors, and bioimpedance monitoring sensors. These sensors are electrically connected to conductive circuits 80 within the woven band 34, which are then connected using rivets 29, eyelets, or grommets 42 that lead to hard electronics 22 (e.g., mounted on PCB 78). In other embodiments, the main electronics PCB 78 also incorporates motion sensors and temperature sensors as part of the electronics 22 in the module PCB 78.

[0033] Figure 17 shows embodiments including underwear, bras, and shirts, which include a woven base material 34 to which a woven shape factor is well applied. It can be understood that the embodiments are applicable to any form of woven base material 34 or a flexible base material 34 exhibiting properties similar to a woven or fabric.

[0034] Figure 18 shows steps relating to attaching the upper textile PCB 28 to the fabric band 34 in this embodiment, which include: (1) placing adhesive material A on the bottom surface of the upper textile PCB 28; (2) inserting the upper textile PCB 28 into the fabric band 34 by aligning the holes 42 of the upper textile PCB 28 with the corresponding pre-punched rivet holes 34b of the fabric band 34; (3) placing double-sided adhesive A on the lower textile PCB 30 and placing it on the opposite side 34a of the fabric band 34 from the upper textile PCB 28, and aligning it with the pre-punched rivet holes 34b of the fabric band 34; and (4) pressing the rivets 29 while applying uniform pressure to the PCBs 28 and 30.

[0035] Steps 1 to 4 described above create a robust and reliable mechanical and electrical connection between the upper textile PCB 28, the lower textile PCB 30, and the fabric band 34. Where electrical connections are required, the pre-punched rivet holes 34b of the fabric band 34 can be positioned such that the conductive circuit 80 of the fabric band 34 makes physical contact with the metal rivet 29 and / or conductive location 42 (e.g., part of the conductive path 43 located on the underside of the first substrate 28) (and thus can be positioned to make direct contact with the surface 34a of the fabric base material 34). Note that the rivet 29 may also mean an eyelet, grommet, or a similar type of metal fastening method.

[0036] The woven band pocket 35 is manufactured to protrude from the surface 34a of the woven band 34, making it easy to remove the module dock housing 50 when needed, while also providing just enough space for the module dock housing 50 to fit snugly inside the pocket 35.

[0037] Figure 19 shows step 106 relating to attaching the module dock 14 and dock backing 32 to the fabric band 34, this embodiment includes the following steps: (1) applying epoxy to the dock 14 and placing it inside the pocket 35 by aligning the heated stacking pole 90 with the holes 28b, 30b of the textile PCBs 28, 30; (2) heat-scribing the dock 14 to the textile PCB 28, 30, 34 assembly; (3) applying epoxy to the dock backing 32 and placing it on the back of the lower textile PCB 30; and (4) covering the dock backing 32 with a fabric, preferably laminated.

[0038] Figure 20 shows step 108 related to attaching the connector PCB 26 to the lower module enclosure 24, which embodiment includes the following steps: (1) placing and press-fitting the connector PCB target disk 26 into the lower module hole 79a; (3) heat-crimping the connector PCB 26 to the dock body 14a; and (4) applying adhesive sealant around the connector PCB 26 to prevent water from entering between the body 14a and the connector 26.

[0039] Figure 21 shows step 110 relating to attaching the light pipe 16 and magnet 20 and the corresponding electronic equipment 22 to the upper module enclosure 18, and attaching the upper module enclosure 18 and the lower module enclosure 24 together, which embodiment includes the following steps: (1) press-fitting and / or bonding the light pipe 16 to the upper module 18; (2) press-fitting and / or bonding the magnet 20 to the upper module 18 and connecting the electronic equipment 22 (e.g., via PCB 28 to the connector 26) to electrically connect the conductive path 76 of the electronic equipment 22 to the connector of the connector 26; (3) attaching the upper 18 and lower 24 of module 12 together; and (4) ultrasonically welding to seal the edges of the upper module 18 and the lower module 24.

[0040] Other manufacturing options, while not limited to the following, may include the following processes:

[0041] 1) The installation process includes the steps of attaching the upper textile PCB to the fabric band, placing adhesive material on the lower dimensions of the upper textile PCB, inserting the upper textile PCB into the fabric pocket by aligning the holes in the upper textile PCB with the corresponding pre-punched rivet holes in the fabric band, placing double-sided adhesive on the lower textile PCB and placing it on the opposite side of the fabric band from the upper textile PCB, and aligning it with the pre-punched rivet holes in the fabric band 34, and pressing the rivets while applying uniform pressure to the PCB.

[0042] 2) In areas where electrical connection is required, pre-punched rivet holes in the fabric band can be positioned so that the conductive circuit of the fabric band makes physical contact with the metal rivet.

[0043] 3) The woven band pocket is manufactured to be raised on the surface of the woven band, providing just enough space for the module dock housing to fit snugly inside the pocket, while also allowing it to be removed when in use.

[0044] 4) Attach the module dock and dock backing to the fabric band, apply epoxy to the dock, position it inside the pocket by aligning the heated stacking pole with the holes in the textile PCB, heat crimp the dock to the fabric PCB assembly, apply epoxy to the dock backing, position it on the back of the lower textile PCB, and cover the dock backing with fabric, preferably laminated.

[0045] 5) Mount the connector PCB into the lower module enclosure, position and press-fit the connector PCB target disk into the lower module hole, heat-crimp the connector PCB into the dock, apply adhesive sealant around the connector PCB to prevent water ingress, and / or

[0046] 6) Attach the light pipe and magnet to the upper module enclosure, attach the upper module enclosure and the lower module enclosure together, press-fit and / or bond the light pipe to the top of the module, press-fit and / or bond the magnet to the top of the module, attach the top and bottom of the module together, and ultrasonically weld the edges of the upper and lower modules to seal them.

[0047] Accordingly, the optimal dimensional relationships of the parts of the present invention, including variations in dimensions, materials, shape, form, function, and method of operation, mounting, and use, are considered to be readily apparent and obvious to those skilled in the art, and it is understood that the present invention is intended to encompass all equivalent relationships with those shown in the drawings and described above.

[0048] Furthermore, other technical fields may also benefit from this method, and adjustments to designs are expected. Therefore, the scope of the present invention should be determined not by the given embodiments, but by the appended "Claims" and their legal equivalents. Embodiments of the present invention for which exclusive rights or privileges are claimed are defined as described in the "Claims."

Claims

1. A docking station assembly that provides a releasable and reliable connection between an electronic controller device and one or more conductive paths of a textile substrate, A modular docking station having a main body fixedly connected to a substrate assembly mounted on a textile substrate, the main body having an exposed electrical docking connector configured to mate with the electrical controller connector of the electronic controller device, A circuit board assembly, A first substrate is placed on one surface of the woven fabric substrate such that one or more first electrical connection points of the first substrate are aligned with one or more conductive paths, and the first substrate has an electrical controller connector mounted thereon, and is electrically connected to one or more of the first electrical connection points by one or more substrate conductive paths, A second substrate, which is placed on the other side of the woven fabric substrate opposite to the one side, and the second substrate has one or more second electrical connection points aligned with the one or more first electrical connection points, A fastener comprising one or more fasteners, wherein one or more second electrical connection points are fixed to one or more first electrical connection points, and thus the fabric base material is firmly fixed between the first substrate and the second substrate, A substrate assembly comprising, Equipped with, A docking station assembly in which one or more of the aforementioned first electrical connection points are in electrical contact with one or more adjacent conductive paths.

2. The docking station assembly according to claim 1, wherein each of the one or more fasteners is conductive and is in physical contact with the one or more conductive paths, and thus contributes to the electrical contact.

3. The docking station assembly according to claim 1, further comprising a woven pocket of the woven base material for receiving the main body.

4. The docking station assembly according to claim 3, wherein the woven pocket is preferably raised on an adjacent surface of the woven base material and manufactured by knitting into the knit structure of the woven base material.

5. The docking station assembly according to claim 2, wherein each of the one or more fasteners is a rivet.

6. The docking station assembly according to claim 1, wherein the one or more first electrical connection points are eyelets or grommets connected to the electrical controller connector via the one or more respective substrate conductive paths.

7. The docking station assembly according to claim 6, wherein each of the one or more substrate conductive paths is a trace of a PCB circuit, and the first substrate is a PCB.

8. The docking station assembly according to claim 1, wherein the woven base material is incorporated into a garment selected from the group consisting of bands, underwear, bras, and shirts.

9. The docking station assembly according to claim 1, further comprising a releasable mechanical connector located on the main body, the releasable mechanical connector facilitating a releasable and secure mechanical connection between the controller device and the main body.

10. The apparatus according to claim 1, wherein the electrical dock connector mates with the electrical controller connector via a pin and socket configuration.

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