Connector Assembly

Abstract

The present invention relates to a connector assembly, a seam tape, a garment, and a method of producing the connector assembly.

Description

[Technical field]

[0001] The present invention relates to a connector assembly, a seam tape, a garment, and a method of producing the connector assembly. [Background technology]

[0002] DE 10 2015 007 157 A1 relates to a flat electrical contact assembly, for example for textile heating elements. The assembly has a sandwich structure with at least one electrically conductive thermoplastic fibre. The electrically conductive fibre is connected to an electrical conductor, for example a flat strand, a highly conductive tape or a metal foil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] DE 10 2015 007 157 A1 [Patent Document 2] European Patent Application No. 19 20 8544.7 Summary of the Invention [Problem to be solved by the invention]

[0004] It is an object of the present invention to provide a mechanically, chemically and electrically robust connector assembly for connecting components of, for example, electronic textiles. Yet another object of the present invention is to provide a connector assembly adapted to establish an electrical connection capable of withstanding mechanical deformations such as stretching and bending and / or chemical influences such as sweating and washing. Yet another object may be found in providing a robust connector assembly that can be produced within a thermal bonding process. [Means for solving the problem]

[0005] These and further objects of the invention are solved by the subject matter of the independent claims. Further embodiments of the invention are set out in the dependent claims, the description and the drawings.

[0006] In the context of this invention, the terms "top", "bottom", "upper", "lower", etc. refer to directions perpendicular to the layers of the connector assembly, with the base material being the bottom layer and the cover fabric being the top layer, i.e., the bottom-to-top direction is from the base material to the cover fabric.

[0007] In the context of the present invention, the term "conductive" refers to electrical conductivity unless otherwise specified. In other words, "conductive" refers to the property of a material to carry an electric current. Preferably, the electrical resistivity of the conductive materials referred to herein is greater than 10 -3 Lower than Ωm.

[0008] The present invention relates to a connector assembly comprising a base material, a first conductive fabric coupled to the base material, a resilient and compressible conductor electrically connected to the first conductive fabric, and a textile cover fabric coupled to the first conductive fabric, such that a portion of the conductor is positioned between the first conductive fabric and the textile cover fabric, the portion of the conductor being at least partially in a compressed state.

[0009] The connector assembly can be adapted to electrically connect, for example, a component of an electronic textile to an electrical conductor. The electronic textile can be part of a garment such as a sports suit, an Electrical Muscle Stimulation Suit (EMS suit), or a garment having means for electronically measuring vital signs such as muscle activity, cardiac activity, or respiration, or a garment having means for electronically measuring environmental parameters that may be related to safety such as temperature, radiation levels, pressure. More specifically, the connector assembly can be adapted to connect a conductor, for example a conductor embedded in an extensible seam tape, to an electrical component such as a body electrode. In other words, a first conductive textile to which the electrical conductor is electrically connected forms a tongue that connects to the electrical component.

[0010] Preferably, the first conductive textile is electrically connected to an electrical component, preferably comprising one or more of the group consisting of a body electrode, a sensor, a heating element, a lighting device, a processing unit, a printed circuit board, an electrical connector, a wire, and a button.

[0011] The connections that can be established with the connector assembly of the invention are able to withstand mechanical deformations such as stretching and / or bending, and / or chemical influences such as perspiration and washing.

[0012] The base material may be a textile fabric, an elastomer, a printed circuit board (PCB), etc. For example, the base material may be part of a garment.

[0013] Preferably, the first conductive fabric comprises knitted, woven, non-woven, or metal mesh fibers. The conductive fabric may comprise non-conductive elements such as polyamide, nylon, acrylic, polyester, elastane, and / or conductive elements such as stainless steel, silver, nickel, copper, copper alloys, tin, zinc, cobalt, manganese, iron, gold, carbon, and combinations thereof.

[0014] Preferably, the first conductive fabric comprises a silver coated textile mesh.

[0015] Preferably, the first conductive fabric is extensible. More preferably, a force of 20N causes an elongation of the first conductive fabric of at least 20%.

[0016] Preferably, the first conductive fabric is elastic, more preferably, the first conductive fabric is extensible and elastic.

[0017] Preferably, the first conductive fabric has a sheet resistance of less than 5 Ω / sq ("ohms per square").

[0018] Preferably, the electrical conductor is an elongated conductor. In the context of the present invention, the term "elongated" refers to the dimension of the conductor rather than its state (stretched vs. unstretched) and is considered to cover any electrical conductor whose length is greater than its diameter (preferably at least 2 times, more preferably at least 10 times).

[0019] The conductor is elastic. Thus, the conductor may be extensible. Preferably, a pull of 0.2 N causes the conductor to elongate by at least 10%. More preferably, a pull of 0.6 N causes the conductor to elongate by at least 50%.

[0020] The electrical conductor preferably has a resistance of 0.1 Ω / m to 100 Ω / m in the quiescent state.

[0021] In the context of the present invention, the term "elastic" refers to a material property of the conductor that requires that the conductor can be elastically stretched with a force achievable by hand at least along the direction of elongation of the conductor, and relax back to an unstretched state when the force is no longer applied. Preferably, the elastic material of the conductor has a Young's modulus of 10 kPa to 1 GPa, more preferably 100 kPa to 100 MPa, and most preferably 100 kPa to 2 MPa. This applies equally to other "elastic" components described herein.

[0022] Furthermore, the conductor is compressible. The term "compressible" means that the conductor can assume a relaxed state and a compressed state, and the size of the conductor, e.g., the diameter or height, is different in the compressed and relaxed states. Preferably, the conductor is compressible at least in a direction perpendicular to the direction of elongation of the conductor. The compressibility of the conductor may be due to its elasticity. Preferably, a force of 5 N causes a local reduction in the size of the conductor of at least 15% along the direction of the force.

[0023] A portion of the conductor is at least partially in compression. Preferably, the portion of the conductor that is positioned between the first conductive fabric and the cover fabric is at least partially in compression. However, it is also contemplated that only a portion of this portion is in compression. Thus, the conductor is compressed along at least one direction, preferably a direction perpendicular to the plane defined by the first conductive fabric, the cover fabric, and / or the base material, when the connector assembly is flat. The term "compressed" means that the diameter or height of the portion of the conductor along at least this direction is smaller than the diameter or height of the portion of the conductor in the relaxed state. Thus, the diameter or height of the conductor can be measured along the pressing direction of the bonding process.

[0024] This can be measured, for example, by comparing a first diameter or height of a portion of the conductor positioned between the first conductive fabric and the cover fabric to a second diameter or height of another portion of the conductor positioned outside the first conductive fabric and the cover fabric. For example, the connector assembly can be cut through the first fabric, the cover fabric, and a portion including the compressed portion of the conductor to measure the first diameter or height of the conductor. Additionally, the conductor can be cut in an area not bonded to the first conductive fabric to measure the second diameter or height of the conductor. By comparing the first diameter or height and the second diameter or height, it can be established that the portion of the conductor is in compression.

[0025] Alternatively, the first diameter or height can be measured after cutting the connector assembly through a portion including the first fabric, the cover fabric, and the compressed portion of the conductor. The connector assembly can then be disassembled, for example by melting the adhesive with hot air. After disassembly, the conductor again assumes a relaxed state due to its elasticity so that a second diameter or height can be measured. By comparing this first diameter or height with this second diameter or height, it can be established that this portion of the conductor is in a compressed state.

[0026] By providing the conductors in compression in the connector assembly, the conductors press against the conductive fabric. In this way, a good and robust electrical connection can be ensured, especially during bending and / or stretching, and after repeated bending and / or stretching. In other words, the conductors are in electrical and mechanical contact with the conductive fabric.

[0027] The textile cover fabric is bonded to the first conductive fabric. The term "bonded" can refer to the act of joining or laminating components by adhesives, heat, pressure, and / or ultrasonics. The term "bonded" can also include ultrasonic welding. By defining a first component (e.g., the first conductive fabric) as being "bonded" to a second component (e.g., the base material), there is a joint established by bonding between the first and second components. To this end, an adhesive layer can be positioned between the first conductive fabric and the base material, and yet another adhesive layer can be positioned between the first conductive fabric and the base material. fabric The first conductive fabric and the base material may be positioned between the first conductive fabric and the cover fabric. fabric and the base material. In this way, each adhesive layer is at least partially melted such that the layers adjacent to the adhesive layer are bonded to each other. Thus, the first conductive fabric can be bonded to the base material by an adhesive layer positioned between the first conductive fabric and the base material. The first conductive fabric can be bonded to the cover material by an adhesive layer positioned between the first conductive fabric and the cover material. This can be achieved by combining the other components disclosed herein, e.g., the first conductive fabric, the base material, the adhesive layer ... fabric and the cover layer bond equally.

[0028] The adhesive layer disclosed herein preferably comprises a resilient polymer such as a thermoplastic low melting point polyurethane. Preferably, the adhesive layer has a melting point of 80°C to 110°C.

[0029] A portion of the conductor is positioned between the first conductive fabric and the cover fabric. In this way, when the first conductive fabric and the cover fabric are hot pressed, the portion of the conductor is compressed and pressed against the first conductive fabric. In this way, a robust electrical and mechanical connection between the conductor and the first conductive fabric can be established. Furthermore, after bonding, the portion of the conductor remains in a compressed state after bonding. The portion of the conductor can be maintained in a compressed state by an adhesive that melts around the conductor at the time of bonding.

[0030] The bonding of the first conductive fabric to the base material and the bonding of the first conductive fabric to the cover fabric can be performed simultaneously by hot pressing an assembly including the base material, the first conductive fabric, the portion of the conductor, and the cover fabric.

[0031] Bonding is preferably carried out by hot pressing the assembly at a temperature of at least 130° C. for at least 20 seconds.

[0032] Preferably, the connector assembly is flexible.

[0033] The term "flexible" means that a load applied to the respective material, e.g., a connector assembly, causes the material, e.g., a connection assembly, to bend. The term "flexible" further means that the material does not yield or break before the 5% strain limit, as defined in ASTM D790, in a three-point deflection test, as defined in ASTM D790.

[0034] Preferably, the connector assembly has a flexural modulus of less than 2.5 GPa, and more preferably, a flexural modulus of less than 20 MPa.

[0035] Preferably, the connector assembly can be bent greater than 90° around a rod having a bend radius of less than 4 mm without breaking / failure.

[0036] Preferably, the connector assembly is extensible.

[0037] The term "extensible" means that a tensile force applied to the respective material, e.g., connector assembly, causes the material, e.g., connector assembly, to elongate. Preferably, a force of 20N causes at least 20% elongation. Preferably, the extensible connector assembly is elastic. For example, a force of 14N causes 20% elongation. This corresponds to a stress of 1.27 MPa, and the elastic modulus is about 6.35 MPa. For example, a force of 24N causes 40% elongation. This corresponds to a stress of 2.2 MPa, and the elastic modulus is about 5.3 MPa. However, this value depends on the adhesive and the fibers.

[0038] Preferably, the height or diameter of the conductor at said portion measured perpendicular to the plane defined by the first conductive fabric is less than 95% of the height or diameter of the conductor measured along the same direction in the relaxed state, preferably less than 90%. Less than , more preferably 80% Less than .

[0039] Preferably, the connector assembly further comprises a second conductive fabric coupled to the cover fabric and the first conductive fabric, the portion of the conductor also being electrically connected to the second conductive fabric and sandwiched between the first and second conductive fabrics.

[0040] That is, the cover fabric can be coupled to the first conductive fabric via the second conductive fabric.

[0041] Preferably, the second conductive fabric has the same properties as the first conductive fabric.

[0042] To bond the second conductive fabric to the cover fabric, an adhesive layer can be positioned between the second conductive fabric and the cover fabric. In the assembled connector assembly, i.e. after bonding, the first conductive fabric can be in mechanical and electrical contact with the second conductive fabric. Furthermore, a conductor can be pressed between the first conductive fabric and the second conductive fabric. Thus, the conductor can be in mechanical and electrical contact with the first conductive fabric and the second conductive fabric.

[0043] By sandwiching that portion of the conductor between the first and second conductive fabrics, the connection between the conductor and the conductive fabric is improved and more robust, especially during bending and stretching, and after repeated bending and stretching.

[0044] Preferably, the electrical conductor comprises a resilient and compressible core and a conductive wire wound around the resilient core.

[0045] The elastic and compressible core preferably comprises an elongated body of natural rubber. The elastic and compressible core may comprise any member of the group comprising elastane, polyurethane, silicone rubber, polyisoprene, polyethylene rubber, polyacrylic rubber, and thermoplastic polyurethane, and combinations thereof. The elastic and compressible core preferably has a diameter perpendicular to the direction of extension of the elastic and compressible core of 0.5 mm to 1.2 mm.

[0046] Preferably, the elastic and compressible core has a round cross-section.

[0047] The conductive wire may comprise any member of the group consisting of copper, copper alloys, silver, stainless steel, aluminum, nickel, tin, zinc, cobalt, manganese, iron, gold, carbon, and combinations thereof. Preferably, the conductive wire is a silver coated copper wire. Preferably, the conductive wire is a Litz wire, for example made up of 5 to 30 wires each having a diameter of 0.02 mm to 0.08 mm.

[0048] The electrical conductor may include a plurality of conductive wires wrapped around an elastic core.

[0049] There may be specific wrapping or winding configurations. Preferably, the conductor comprises two conductive wires wound around an elastic core with opposite winding directions and at least 5 turns / cm.

[0050] By providing the conductor with such a structure, the conductor can have improved elasticity and compressibility, thus also improving the connection of the conductor with the conductive fabric or fabrics, and in particular making it more robust.

[0051] Preferably, the electrical conductor further comprises a non-conductive textile thread wound around the elastic core.

[0052] Preferably, one or more electrical wires can be wrapped around a non-conductive textile yarn, and this arrangement can then be wrapped around an elastic core.

[0053] Preferably, the electrical conductor comprises conductive particles embedded in a host material.

[0054] For example, the conductor may comprise an elastomer as a matrix filled with dendritic silver particles as conductive particles. Above a certain particle content, the particles contact each other, resulting in the formation of conductive paths within the conductive composite. The conductor may have a diameter of 0.1 mm to 3 mm, preferably 0.3 mm to 2 mm. However, it is contemplated that the conductor need not be round, but may have a flat profile, for example with a thickness of 0.05 mm to 0.5 mm and a width of 0.5 mm to 3 mm. The particles preferably have an average size between 1 μm and 50 μm, more preferably between 10 μm and 30 μm. The particle content of the composite is preferably 20% to 35% by volume, more preferably 20% to 30% by volume. The resistance of the conductor is preferably between 1 Ω / m and 100 Ω / m at rest.

[0055] The matrix may comprise one or a combination of the following materials: polyurethane, silicone rubber, polydimethylsiloxane, polyisoprene, styrene butadiene rubber, ethylene propylene diene monomer rubber, polychloroprene rubber, chlorosulfonyl polyethylene rubber, acrylonitrile butadiene rubber, polyacrylic rubber, ethylene acrylic rubber, epichlorohydrin rubber, polyisobutylene rubber, hydrogenated nitrile rubber, fluororubber, fluorosilicone rubber, perfluorocarbon rubber, polyurethane, styrenic block copolymer, thermoplastic olefin, elastomeric alloy, thermoplastic copolyester, thermoplastic polyamide.

[0056] The conductive particles within the conductor matrix can comprise any conductive material, preferably one or a combination of the following components: Ag coated glass particles, Ag coated Cu particles, Ag coated metal particles, Au coated metal particles, copper particulates, copper nanoparticles, silver particulates, silver nanoparticles, nanowires, metal particulates, nanotubes (e.g., carbon nanotubes), flakes (e.g., metal flakes), graphene, aluminum particulates, gold particulates, tin particulates, copper nanowires, silver nanowires, aluminum nanowires, gold nanowires, tin nanowires, copper flakes, silver flakes, aluminum flakes, gold flakes, tin flakes, carbon particles, graphite particles.

[0057] By providing a conductive element with such a configuration, the conductive element can have improved elastic modulus and compressibility, and thus the connection of the conductor with the conductive fabric(s) is improved and more robust, particularly during bending and / or stretching, as well as after repeated bending and / or stretching.

[0058] Preferably, the connector assembly further comprises an adhesive layer positioned at least between the first conductive fabric and the conductor, and, if present, between the first conductive fabric and the second conductive fabric.

[0059] More preferably, the adhesive layer is fabric does not cover the entire area.

[0060] More preferably, the adhesive layer is perforated.

[0061] The adhesive layer is a first conductive fabric Preferably, the adhesive layer covers no more than 90%, more preferably no more than 80%, and even more preferably about 75% of the surface of the electrical conductor. In particular, the adhesive layer may not cover the entire portion of the electrical conductor that is located between the first conductive fabric and the cover fabric or the second conductive fabric.

[0062] The perforations in the adhesive layer may be uniformly distributed throughout the adhesive layer. The perforations preferably have a size of 0.1 mm to 3 mm, more preferably 1 mm to 2 mm. The adhesive layer is preferably 16 mm 2 More preferably, the plate has at least 3, more preferably at least 10 perforations per plate.

[0063] By providing an adhesive layer, which does not cover the entire area of ​​the first conductive fabric or is perforated, between the first conductive fabric and the conductor, and also between the first conductive fabric and the second conductive fabric, if present, it can be ensured that the contact area between the conductor and the first conductive fabric and the second conductive fabric, if present, is large enough to provide an improved electrical connection while ensuring a reliable and robust bond between the first conductive fabric and the second conductive fabric. In the bonding process, the mechanical and electrical contact between the conductor and the first conductive fabric and optionally the second conductive fabric can be established before the adhesive is melted to fill the voids between and within the fabrics. The amount of adhesive can be selected to ensure proper bonding between the layers. After bonding, the adhesive of the adhesive layer can be solidified and / or stretched around the conductor to maintain compression of the conductor.

[0064] Alternatively, the adhesive layer may not be positioned between the first conductive fabric and the second conductive fabric. In this case, during bonding, the adhesive of the adhesive layer positioned between the second conductive fabric and the cover fabric can extend or melt through the second conductive fabric to contact the first conductive fabric. Alternatively or additionally, during bonding, the adhesive of the layer positioned between the first conductive fabric and the base material can extend or melt through the first conductive fabric to contact the second conductive fabric.

[0065] Thus, the adhesive of each adhesive layer is used to bond the second conductive fabric and the first conductive fabric.

[0066] In the bonding process, mechanical and electrical contact between the conductors and the first and second conductive fabrics can be established before the adhesive melts to fill voids between and within the fabrics. The amount of adhesive in the adhesive layer positioned between the second conductive fabric and the cover fabric and / or the adhesive layer positioned between the base material and the first conductive fabric can be selected to ensure proper bonding between the layers, particularly between the first and second conductive fabric layers. After bonding, adhesive that extends or melts through the first and / or second conductive fabrics can be positioned around the conductors to maintain compression of the conductors.

[0067] Preferably, the cover fabric is not extensible. Providing a non-extensible cover fabric will help limit the strain applied to the connector assembly, thus resulting in improved mechanical stability of the connector assembly.

[0068] Preferably, the cover fabric is extensible, and more preferably, the cover fabric is at least partially in an extensible state.

[0069] Preferably, a portion of the cover fabric located above the first conductive fabric and / or the second conductive fabric is at least partially in an extended state.

[0070] The term "extensible" means that the cover fabric can be stretched along at least one direction. Thus, the cover fabric has a relaxed state and an extended state, and the length of the cover fabric along this direction is greater in the extended state than in the relaxed state. Preferably, a force of 20 N causes an elongation of at least 20%, preferably at least 30%.

[0071] The cover fabric may be elastic.

[0072] Alternatively, the adhesive layer positioned between the cover fabric and the first or second conductive fabric is elastic, so that after bonding, the cover fabric can be elastic.

[0073] For example, the portion of the cover fabric can be in tension along the direction of elongation of the portion of the conductor located between the first conductive fabric and the cover fabric and / or the second conductive fabric, and the cover fabric can also be in tension along one or more additional directions, such as a direction perpendicular to the direction of elongation of the portion of the conductor.

[0074] Similarly, an adhesive layer positioned between the cover fabric and the first or second conductive fabric can be in an expanded state.

[0075] The term "stretched state" can mean that the cover fabric has an elongation along a stretch direction that is greater than the elongation of the cover fabric along this direction in the relaxed state. Preferably, in the stretched state, the local elongation of the cover fabric is at least 5% greater than the relaxed state of the cover fabric.

[0076] The elongation of the cover fabric in a stretched state can be determined by measuring the elongation of the cover fabric in an assembled connector assembly, and the elongation of the cover fabric in a relaxed state can be determined by disassembling the connector assembly, e.g., by melting the adhesive layer to release the bond, and measuring the elongation of the cover fabric after relaxation, e.g., by applying hot air.

[0077] By providing the cover fabric in a stretched state, the connection between the conductors and the first and / or second conductive fabrics can be further improved and made more robust. In particular, the stretched elastic cover fabric can further press the conductors against the first and / or second conductive fabrics. In this way, the localized compression forces provide a robust electrical contact, in particular during bending and / or stretching, as well as after repeated bending and / or stretching.

[0078] The present invention further relates to an assembly including a seam tape and a connector assembly as disclosed herein, the electrical conductor being at least partially embedded in the seam tape. Preferably, the seam tape comprises a fibrous elastic top layer, a first adhesive layer, and a second adhesive layer, the electrical conductor being at least partially sandwiched between the first adhesive layer and the second adhesive layer.

[0079] The seam tape may be an elongated elastic seam tape such as that disclosed in European Patent Application No. 19 20 8544.7.

[0080] The adhesive layers may also function as insulating layers. Each of the adhesive layers may include one or more members selected from the group consisting of elastomeric polymers such as thermoplastic polyurethanes, silicones, polyethylenes, polyolefins, and thermoplastic polyamides. Each adhesive layer may have a thickness of 0.025 mm to 1 mm.

[0081] Preferably, each adhesive layer has a three-layer structure, with a middle layer covered on both sides by an outer layer. The middle layer may have a higher melting point than the outer layer. The melting point of the middle layer may be higher than 150°C. The outer layer may have a melting point of 80°C to 110°C.

[0082] The intermediate layer may comprise a material selected from the group comprising polymers such as thermoplastic high melt temperature polyurethanes, preferably having a melting point greater than 150° C., silicones, polyethylenes, polyolefins, and / or thermoplastic polyamides. The intermediate layer may have a thickness of 0.025 mm to 1 mm.

[0083] The outer layers may comprise a thermoplastic low melting temperature polyurethane, preferably having a melting point of 80° C. to 110° C. Each outer layer may have a thickness of 0.01 mm to 1 mm.

[0084] The top layer may comprise an elastic fibre, such as a Lycra-based elastic ribbon, an elastic polymer, such as silicone or polyurethane. The top layer may have a thickness of 0.1 mm to 1 mm.

[0085] The seam tape may have a width of 5mm to 20mm, preferably 8mm to 12mm, more preferably 10mm.

[0086] The present invention further relates to a garment comprising the connector assembly disclosed herein or an assembly comprising a seam tape and a connector assembly.

[0087] Preferably, the garment is a sports suit, an Electrical Muscle Stimulation suit (EMS suit), or a garment having means for electronically measuring vital signs such as muscle activity, cardiac activity, or respiration, or a garment having means for electronically measuring environmental parameters that may be relevant for safety such as temperature, radiation levels, pressure.

[0088] The present invention further relates to a method of producing a connector assembly, preferably as disclosed herein, comprising the steps of providing a base material, bonding a first conductive fabric to the base material, disposing a resilient and compressible electrical conductor on the first conductive fabric, preferably electrically connecting the electrical conductor to the first conductive fabric, and bonding a textile cover fabric to the first conductive fabric such that a portion of the electrical conductor is positioned between the first conductive fabric and the cover fabric, after bonding, the portion of the electrical conductor is at least partially in compression.

[0089] The descriptions, specifications and technical effects disclosed with reference to the connector assembly also apply to the method of producing the connector assembly, in particular the material properties of the different layers disclosed with reference to the connector assembly also apply to the materials used in the method.

[0090] The step of bonding the first conductive fabric to the base material can be performed before, during or after bonding the cover fabric to the first conductive fabric. Preferably, the steps are performed in the following order: first, the first conductive fabric is placed on the base material and these layers are bonded; second, the conductor is placed on the first conductive fabric; third, the cover fabric is placed on the first conductive fabric and the conductor and bonded to the first conductive fabric. In this way, the first conductive fabric is bonded to the base material and the conductor is electrically connected to the first conductive fabric. Alternatively, first, all layers can be stacked and then bonded in only one bonding step.

[0091] In bonding the cover fabric to the first conductive fabric, the electrical conductors may be pressed against the first conductive fabric, thereby establishing an electrical connection.

[0092] Preferably, in any of the bonding steps disclosed herein, bonding is carried out by hot pressing the assembly, more preferably at a temperature of at least 130° C. for at least 20 seconds.

[0093] Preferably, any of the bonding steps disclosed herein, particularly the step of bonding the second conductive fabric to the first conductive fabric, preferably includes a cooling stage after hot pressing. More preferably, pressure is maintained during the cooling stage. In this way, compression on the connector assembly is maintained as the adhesive fully solidifies and the electrical connector is maintained in compression.

[0094] It is understood that the first conductive fabric can be bonded to the base material with an adhesive layer positioned at least between the first conductive fabric and the base material, and the cover fabric can be bonded to the first conductive fabric with an adhesive layer positioned at least between the first conductive fabric and the cover fabric.

[0095] Preferably, before bonding, the conductor has a height h0 measured along the pressing direction. After bonding, the conductor has a height h1 measured along the pressing direction. The height h1 is less than the height h0, preferably h1<0.95. * h0, more preferably h1<0.9 * h0, and even more preferably h1<0.8 * The value is h0.

[0096] The pressing direction can be perpendicular to a plane defined by the base material, the first conductive fabric, the second conductive fabric, and / or the cover fabric when the layers are flat.

[0097] Preferably, the method further comprises adhering a second conductive fabric to the first conductive fabric such that the portion of the conductor is sandwiched between the first and second conductive fabrics, and adhering the textile cover fabric to the second conductive fabric such that the textile cover fabric is coupled to the first conductive fabric via the second conductive fabric.

[0098] It is understood that the second conductive fabric can be adhered to the cover fabric with an adhesive layer positioned at least between the second conductive fabric and the cover fabric.

[0099] The step of adhering the second conductive fabric to the cover fabric can be performed after bonding the first and second conductive fabrics. Preferably, the steps are performed in the following order: first, the first conductive fabric is placed on a base material and these layers are bonded; second, the conductor is placed on the first conductive fabric; third, the second conductive fabric is placed on the first conductive fabric; fourth, the cover fabric is placed on the second conductive fabric; fifth, the second conductive fabric and the cover fabric are bonded to the first conductive fabric. Alternatively, all layers can be first stacked and then bonded in only one bonding step.

[0100] Preferably, the step of bonding the first and second conductive fabrics is carried out by hot pressing at least the first conductive fabric, this portion of the conductor, and the second conductive fabric, more preferably the hot pressing is carried out at a temperature of at least 130° C. for at least 20 seconds.

[0101] In this manner, the electrical conductors are maintained in compression against the first and second conductive fabrics, thereby providing an improved and more robust electrical and mechanical connection of the electrical conductors with the first and / or second conductive fabrics.

[0102] Preferably, no adhesive layer is disposed between the first and second conductive fabrics prior to bonding.

[0103] Preferably, in the bonding step, an adhesive layer positioned between the second conductive fabric and the cover fabric can melt or extend through the second conductive fabric to contact the first conductive fabric.

[0104] Alternatively or additionally, in the bonding process, an adhesive layer positioned between the first conductive fabric and the base material can melt or extend through the first conductive fabric to contact the second conductive fabric.

[0105] Additionally, the adhesive extending or melting through the first and / or second conductive fabrics may extend or melt around a portion of the conductor to maintain this portion of the conductor in compression.

[0106] This can ensure proper electrical connection between the electrical conductor and the first and second conductive fabrics.

[0107] To this end, the bonding of the first and second conductive textiles can be carried out at a minimum temperature during a minimum bonding time, preferably at a temperature of at least 130° C. and a bonding time of at least 20 seconds, more preferably at a temperature of at least 150° C. and a bonding time of at least 30 seconds.

[0108] By omitting the adhesive layer between the first and second conductive fabrics, the amount of adhesive positioned between the conductor and the first and / or second conductive fabrics prior to bonding can be reduced, and the contact area between the conductor and the first and / or second conductive fabrics prior to bonding can be increased, thus improving the electrical connection between the conductor and the conductive fabrics.

[0109] Preferably, the method further comprises the step of placing an adhesive layer between the first conductive fabric and the cover fabric or, when present, the second conductive fabric prior to bonding. More preferably, the adhesive layer is fabric Even more preferably, the adhesive layer is perforated.

[0110] By providing an adhesive layer that does not cover the entire area of ​​the first conductive fabric or that is perforated, it can be ensured that the contact area between the conductor and the first conductive fabric, and, if present, the second conductive fabric, is large enough to provide an improved electrical connection while ensuring a reliable and robust bond between the first and second conductive fabrics.

[0111] Preferred embodiments of the invention will be further elucidated below with reference to the drawings, in which: [Brief description of the drawings]

[0112] [Figure 1] FIG. 2 illustrates an exploded view of a connector assembly and seam tape assembly according to an exemplary embodiment of the present invention. [Figure 1A] 2 is a cross-sectional view taken along plane B shown in FIG. 1. [Figure 1B] 2 is a cross-sectional view taken along plane A shown in FIG. 1. [Diagram 2] FIG. 2 shows the assembly of FIG. 1 in an assembled state. [Figure 2B] 3 is a cross-sectional view taken along plane B shown in FIG. 2. [Figure 2C] 3 is a cross-sectional view taken along plane C shown in FIG. 2. [Diagram 3] 13 is a cross-sectional view of an assembly according to another exemplary embodiment of the present invention. [Figure 4] FIG. 2 illustrates an exploded view of a connector assembly and seam tape assembly according to an exemplary embodiment of the present invention. [Figure 5A] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 5B] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 5C] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 5D] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 6A] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 6B] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 6C]1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 6D] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. [Figure 6E] 1A-1D illustrate an assembly at different stages of a method for producing a connector assembly according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0113] 1 illustrates in an exploded view an exemplary embodiment of an assembly including a seam tape 116 and a connector assembly 100. It should be noted that the exploded view of FIG. 1 is provided for illustrative purposes and does not necessarily represent the actual sequence of manufacturing steps.

[0114] The assembly includes a base material 102, for example a fiber-based woven fabric. The connector assembly 100 is provided on the base material 102 and has a layered structure. The layered structure includes a first conductive woven fabric 104 positioned on the base material 102 and bonded to the base material 102 by a first adhesive layer 112, the first adhesive layer 112 being positioned between the first conductive woven fabric 104 and the base material 102. The adhesive of the first adhesive layer 112 can extend at least partially into the first conductive woven fabric 104.

[0115] The connector assembly 100 further includes a conductor 106, at least a portion 126 of the conductor being a first conductive fabric 104. The electrical conductors 106 can be at least partially embedded in the seam tape 116. The seam tape 116 comprises a first adhesive layer 120 and a second adhesive layer 122 between which the electrical conductors 106 are positioned, i.e., sandwiched. Additionally, the seam tape 116 comprises a fibrous elastic top layer 118.

[0116] The connector assembly 100 further includes a second conductive fabric 108 positioned over at least the portions 126 of the first conductive fabric 104 and the electrical conductors 106. The second conductive fabric 108 is bonded to the fabric cover fabric 110 via a second adhesive layer 114. The adhesive of the second adhesive layer 114 can extend at least partially into the second conductive fabric 108. Additionally, a portion of a seam tape 116 can also be sandwiched between the first conductive fabric 104 and the second conductive fabric 108.

[0117] The first conductive fabric 104 is bonded to the second conductive fabric 108. In this exemplary embodiment, a perforated adhesive layer 130 is disposed between the first conductive fabric 104 and the second conductive fabric 108.

[0118] In the mating process, the conductors 106 are compressed such that at least this portion 126 of the conductors 106 is in compression within the assembled connector assembly 100 .

[0119] This exemplary embodiment includes a perforated adhesive layer 130 positioned between the first conductive fabric 104 and the second conductive fabric 108, although this adhesive layer 130 can be omitted, as shown, for example, in FIG. 3.

[0120] Additionally, although this exemplary embodiment includes a first conductive fabric 104 and a second conductive fabric 108, the connector assembly 100 of the present invention does not necessarily include the second conductive fabric 108. That is, the second conductive fabric 108 may be omitted (not shown). This is illustratively shown in FIG.

[0121] Figure 1A is a cross-sectional view taken along plane B shown in Figure 1. Electrical conductor 106 is shown to include a resilient and compressible core 132 and two conductive wires 134, 136 wrapped around the compressible core.

[0122] Alternatively, the electrical conductor may include a substrate (not shown) that includes a matrix material having particles of conductive material embedded therein.

[0123] FIG. 1B is a cross-sectional view taken along plane A shown in FIG.

[0124] Figure 2 shows the assembly of Figure 1 in an assembled and bonded state, Figure 2B is a cross-sectional view along plane B shown in Figure 2, and Figure 2C is a cross-sectional view along plane C shown in Figure 2.

[0125] That is, the cover fabric 110 and the second conductive fabric 108 are bonded to the first conductive fabric 104 and the base fabric 102 .

[0126] The first conductive fabric 104 is bonded to the second conductive fabric 108 with a perforated adhesive layer 130. Additionally, portions of the cover fabric 110 extending above the first conductive fabric 104 and the second conductive fabric 108 are bonded to the base material 102 and / or the top layer 118 of the seam tape 116, and / or the first conductive fabric 104 and / or the second conductive fabric 108.

[0127] In this combined state, at least that portion 126 of the conductor 106 positioned between the first conductive fabric 104 and the second conductive fabric 108 is in compression. As shown, the portion of the conductor 106 sandwiched between the base material 102 and the cover fabric 110 has a height h1 that is less than the height h0 of the portion of the conductor 106 that is not sandwiched between the base material 102 and the cover fabric 110.

[0128] This is best shown in FIG. 2B, which is a cross-sectional view along plane B shown in FIG. 2. As shown, the conductor 106, particularly the elastic and compressible core 132, is in a compressed state and takes an elliptical shape. The conductor 106, particularly the core 132, has a height h1 along a direction perpendicular to the plane defined by the base material 102, the first conductive fabric 104, the second conductive fabric 108, and / or the cover fabric 110. In comparison, FIG. 2C shows a cross-sectional view along plane C shown in FIG. 2. As shown, the conductor is not in a compressed state, i.e., it is in a relaxed state, takes a height h0, and h1 < h0. Similarly, FIG. 1A shows that the conductor 106 is in a relaxed state taking a height h0. By comparing the height h1 of the conductor 106 in the compressed state (FIG. 2B) and the height h0 in the relaxed state (FIGS. 2C, 1A), it can be verified that the conductor 106 is in a compressed state.

[0129] Furthermore, a portion of the conductor 106 that is also positioned at the seam tape 116 can be in a compressed state. That is, a portion of the seam tape 116 can be positioned between the first conductive fabric 104 and the second conductive fabric 108. In this portion of the seam tape 116, the conductor 106 can be in a compressed state.

[0130] The connector assembly is used to connect the conductor 106 to an electrical component. In this exemplary embodiment, the electrical component is the snap button 124.

[0131] FIG. 3 is a cross-sectional view along plane B shown in FIG. 2 of an assembly according to yet another exemplary embodiment.

[0132] As shown, in this exemplary embodiment, no perforated adhesive layer is positioned between the first conductive fabric 104 and the second conductive fabric 108. In this exemplary embodiment, the adhesive of the second adhesive layer 114 extends through or melts through the second conductive fabric 108 and the first conductive fabric 104.

[0133] Separately, the assembly has the same structure as the assembly shown in FIG. 1.

[0134] FIG. 4 shows yet another exemplary embodiment of an assembly including a seam tape 116 and a connector assembly 100 in an exploded view. In contrast to the assemblies shown in FIGS. 1 to 3, the connector assembly does not include a second conductive fabric. The remaining components shown and labeled in FIG. 4 are identical to those shown and labeled in FIG. 1. Thus, the connector assembly 100 includes a base material 102 and a first conductive fabric 104 positioned on the base material 102 and bonded to the base material 102 with a first adhesive layer 112, the first adhesive layer 112 being positioned between the first conductive fabric 104 and the base material 102. A portion of the electrical conductor 106 is positioned on the first conductive fabric. A cover fabric 110 is positioned on at least the first conductive fabric 104. 4, the cover fabric 110 can also extend above the first conductive fabric 104 such that the cover fabric 110 also covers a portion of the seam tape 116 and / or a portion of the base material 102. The second adhesive layer 114 is positioned at least between a side of the first conductive fabric 104 and the conductors 106 and a side of the cover fabric 110 such that the cover fabric 110 is bonded to at least the first conductive fabric by the second adhesive layer 114.

[0135] An exemplary embodiment of a method for producing a connector assembly will now be described with reference to Figures 5A-5D and 6A-6E.

[0136] Figures 5A to 5D show an assembly 100 at different stages of a method for producing a connector assembly. At the final stage shown in Figure 5D, the assembly 100 corresponds to the assembly 100 shown in Figure 4. The reference numbers used in Figures 5A to 5D indicate the same elements as those described above with reference to Figure 4.

[0137] 5A shows a first stage of the method in which a base material 102, a first conductive fabric 104, electrical conductors 106, and a cover fabric 110 are provided. The first conductive fabric 104 includes an adhesive layer 112 that will be disposed between the first conductive fabric 104 and the base material 102. The electrical conductors 106 are at least partially embedded in a seam tape 116. The cover fabric 110 is provided with an adhesive layer 114 that will be positioned between the first conductive fabric 104 and the cover fabric 110, and in some cases also between the base material 102 and / or the seam tape 116 and the cover fabric 110.

[0138] FIG. 5B shows a second stage of the method after the first conductive fabric 104 has been bonded to the base material 102 by the adhesive layer 112 .

[0139] 5C illustrates a third stage of the method, where at least a portion of the conductors 106 that are not embedded within the seam tape 116 are disposed over the first conductive fabric 104. Additionally, a cover fabric 110 is disposed over this portion of the conductors 106, the first conductive fabric 104, and possibly the base material 102 and / or the seam tape 116.

[0140] 5D shows a fourth stage of the method after bonding of the cover fabric 110 to the first conductive fabric 104 and possibly also to the base material 102 and / or seam tape 116 by the adhesive layer 114. As shown, at least the portion of the conductor 106 sandwiched between the first conductive fabric 104 and the cover fabric 110, in this embodiment the portion of the conductor 106 sandwiched between the base material 102 and the cover fabric 110, is in a compressed state, i.e. this portion of the conductor 106 has a height h1 that is lower than the height h0 of the portion of the conductor 106 that is not positioned between the base material 102 and the cover fabric 110.

[0141] Figures 6A to 6E show assembly 100 at different stages of a method for producing a connector assembly. At the final stage shown in Figure 6E, assembly 100 corresponds to assembly 100 shown in Figure 2. The reference numbers used in Figures 5A to 5D indicate the same elements as those described above with reference to Figure 4.

[0142] 6A shows a first stage of the method in which a base material 102, a first conductive fabric 104, electrical conductors 106, a perforated adhesive layer 130, a second conductive fabric 108, and a cover fabric 110 are provided. The first conductive fabric 104 comprises an adhesive layer 112 which will be disposed between the first conductive fabric 104 and the base material 102. The electrical conductors 106 are at least partially embedded in a seam tape 116. The cover fabric 110 is provided with an adhesive layer 114 which will be positioned between the first conductive fabric 104 and the cover fabric 110, and possibly also between the base material 102 and / or the seam tape 116 and the cover fabric 110.

[0143] FIG. 6B shows a second stage of the method after the first conductive fabric 104 has been bonded to the base material 102 by the adhesive layer 112 .

[0144] FIG. 6C illustrates a third stage of the method in which at least a portion of the electrical conductor 106 is disposed on the first conductive fabric 104.

[0145] 6D illustrates a fourth stage of the method, where the perforated adhesive layer 130 is disposed over the portion of the conductors 106 and the first conductive fabric 104. A second conductive fabric is then disposed over the perforated adhesive layer 130 such that the portion of the conductors 106 and the perforated adhesive layer 130 are sandwiched between the first conductive fabric 104 and the second conductive fabric 108. A cover fabric 110 is then disposed over the second conductive fabric 108, and possibly over the base material 102 and / or seam tape 116.

[0146] 6E shows a fifth stage of the method after bonding the second conductive fabric 108 to the first conductive fabric 104 by the perforated adhesive layer 130. Furthermore, the cover fabric 110 is bonded to the second conductive fabric 108 and possibly also to the base material 102 and / or seam tape 116 by the adhesive layer 114. As shown, at least the portion of the conductor 106 sandwiched between the first conductive fabric 104 and the second conductive fabric 108, in this embodiment the portion of the conductor 106 sandwiched between the base material 102 and the cover fabric 110, is in a compressed state. That is, this portion of the conductor 106 has a height h1 that is lower than the height h0 of the portion of the conductor 106 that is not located between the base material 102 and the cover fabric 110.

Claims

1. An assembly including a seam tape (116) and a connector assembly (100), The connector assembly (100) comprises: A base material (102); a first conductive fabric (104) bonded to the base material (102); a resilient and compressible conductor (106) electrically connected to the first conductive fabric (104); a textile cover fabric (110) coupled to the first conductive fabric (104), with a portion (126) of the electrical conductor (106) positioned between the first conductive fabric (104) and the textile cover fabric (110); Equipped with a portion of the electrical conductor (106) is at least partially in compression; The electrical conductor (106) is at least partially embedded in the seam tape (116); The seam tape (116) comprises a fibrous elastic top layer (118), a first adhesive layer (120), and a second adhesive layer (122), and the electrical conductor (106) is at least partially sandwiched between the first adhesive layer (120) and the second adhesive layer (122). Assembly comprising:

2. a height of the conductor (106) within the portion of the conductor (106) measured perpendicular to a plane defined by the first conductive fabric (104) is less than 95% of the height of the conductor (106) in a relaxed state; The assembly of claim 1 .

3. a height of the conductor (106) within the portion of the conductor (106) measured perpendicular to a plane defined by the first conductive fabric (104) is less than 90% of the height of the conductor (106) in a relaxed state; The assembly of claim 1 .

4. a height of the conductor (106) within the portion of the conductor (106) measured perpendicular to a plane defined by the first conductive fabric (104) is less than 80% of the height of the conductor (106) in a relaxed state; The assembly of claim 1 .

5. a second conductive fabric (108) coupled to the cover fabric (110) and the first conductive fabric (104); Further comprising: the portion (126) of the electrical conductor (106) is electrically connected to the second conductive fabric (108) and is sandwiched between the first conductive fabric (104) and the second conductive fabric (108); 5. An assembly according to any one of claims 1 to 4.

6. The electrical conductor (106) comprises a resilient and compressible core (132) and a conductive wire (134, 136) wrapped around the resilient and compressible core (132).

6. An assembly according to any one of claims 1 to 5.

7. The electrical conductor (106) further comprises a non-conductive textile yarn wrapped around the elastic core (132).

7. The assembly of claim 6.

8. The electrical conductor (106) comprises conductive particles embedded in an elastomeric matrix.

6. An assembly according to any one of claims 1 to 5.

9. the connector assembly further comprising an adhesive layer (130) positioned between the first conductive fabric (104) and the second conductive fabric (108); the adhesive layer (130) does not cover the entire area of ​​the first conductive fabric (104); Assembly according to any one of claims 6 to 8 dependent on claim 5.

10. The adhesive layer (130) is perforated.

10. The assembly of claim 9.

11. The cover fabric (110) is extensible.

11. An assembly according to any one of claims 1 to 10.

12. The cover fabric (110) is at least partially in an expanded state.

12. The assembly of claim 11.

13. A method of producing a connector assembly (100), comprising: Providing a base material (102); bonding a first conductive fabric (104) to the base material (102); disposing a resilient and compressible electrical conductor (106) on the first conductive fabric (104), the electrical conductor (106) being electrically connected to the first conductive fabric (104); bonding a textile cover fabric (110) to the first conductive fabric (104) such that a portion of the electrical conductor (106) is positioned between the first conductive fabric (104) and the cover fabric (110); Equipped with After the bonding step, the portion (126) of the electrical conductor (106) is at least partially in compression; coupling a second conductive fabric (108) to the first conductive fabric (104) such that the portion (126) of the conductor (106) is sandwiched between the first conductive fabric (104) and the second conductive fabric (108); a step of bonding the textile cover fabric (110) to the second conductive fabric (108) such that the textile cover fabric (110) is bonded to the first conductive fabric (104) via the second conductive fabric (108); A method for providing the above.

14. Prior to the bonding step, the conductor (106) has a height h0 measured along a pressing direction, After the bonding step, the conductor (106) has a height h1 measured along the pressing direction, h1<0.95 * h0, The method of claim 13.

15. Prior to the bonding step, the conductor (106) has a height h0 measured along a pressing direction, After the bonding step, the conductor (106) has a height h1 measured along the pressing direction, h1<0.9 * h0, The method of claim 13.

16. Prior to the bonding step, the conductor (106) has a height h0 measured along a pressing direction, After the bonding step, the conductor (106) has a height h1 measured along the pressing direction, h1<0.8 * h0, The method of claim 13.

17. the step of bonding the first conductive fabric (104) and the second conductive fabric (108) is performed by hot pressing the first conductive fabric (104), the portion (126) of the conductor (106), and the second conductive fabric (108). The method of claim 13.

18. The hot pressing is carried out at a temperature of at least 130° C. for at least 20 seconds.

20. The method of claim 17.

19. no adhesive layer is disposed between the first conductive fabric (104) and the second conductive fabric (108) prior to the bonding step; 19. The method according to any one of claims 13 to 18.

20. an adhesive layer is positioned between the base material and the first conductive fabric, and in the step of bonding the first conductive fabric to the base material, the adhesive layer positioned between the base material and the first conductive fabric melts or extends through the first conductive fabric and contacts the second conductive fabric; and / or an adhesive layer is positioned between the second conductive fabric and the cover fabric, and in the step of bonding the second conductive fabric to the first conductive fabric, the adhesive layer positioned between the second conductive fabric and the cover fabric melts or extends through the second conductive fabric and contacts the first conductive fabric; 20. The method of claim 19 .

21. disposing an adhesive layer (130) between the first conductive fabric (104) and the second conductive fabric (108) prior to the bonding step; Further comprising: the adhesive layer (130) does not cover the entire area of ​​the first conductive fabric (104); 19. The method according to any one of claims 13 to 18.

22. The adhesive layer (130) is perforated.

22. The method of claim 21.

23. A method according to any one of claims 13 to 22, characterized in that it produces an assembly according to any one of claims 1 to 12.

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