Conductive yarns with insulated coating and methods of assembling textiles including same

Abstract

A textile body and methods of producing textile bodies are disclosed. The textile body may include a first conductive yarn including: a conductive fiber; a hydrophobic layer coating the conductive fiber to form a composite conductive fiber; and a thermoplastic layer coating the composite conductive fiber. The textile body may include a second conductive yarn electrically coupled to the first conductive yarn at one or more engagement points, the one or more engagement points coated by a combination of melted portions of the hydrophobic layer and the thermoplastic layer based on annealing operations. The annealing operations may direct heat proximal to the one or more engagement points to electrically couple the first conductive yarn and the second conductive yarn by melting the hydrophobic layer and the thermoplastic layer at the one or more engagement points.

Description

CONDUCTIVE YARNS WITH INSULATED COATING AND METHODS OF ASSEMBLING TEXTILES INCLUDING SAMECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from U.S. provisional patent application number 63 / 572,612, entitled “CONDUCTIVE YARNS WITH INSULATED COATING AND METHODS OF ASSEMBLING TEXTILES INCLUDING SAME”, filed on April 1 , 2024, the entire contents of which are hereby incorporated by reference herein.FIELD

[0002] Embodiments of the present disclosure generally relate to the field of textile computing systems, and in particular to textile bodies including a combination of conductive and non- conductive yarns.BACKGROUND

[0003] Textile computing systems may include textile bodies having a combination of non- conductive yarns and integrated conductive yarns, thereby providing circuit structures. In some examples, circuit structures may be configured as sensors, actuators, or for coupling with electronic devices for providing smart textiles.SUMMARY

[0004] Textile computing platforms may include conductive yarns or fibers integrated in a textile body for interconnecting circuit devices. In some embodiments, such circuit devices may be configured from conductive yarns to provide sensor devices or actuator devices.

[0005] In some scenarios, conductive yarns for interconnecting circuit devices may be uninsulated. Uninsulated conductive yarns may be susceptible to unintended deterioration of desirable yarn properties. Deterioration of desired properties may include physical damage during textile body manufacturing, or during physical contact with environmental elements during use. In some other scenarios, deterioration of physical properties may include short circuiting with proximally positioned conductive yarns. The present disclosure describes embodiments of conductive yarns having insulative coatings thereon.

[0006] In some scenarios, a manufacturing process for producing textile computing platforms may include constructing one or more textile bodies having conductive yarns or non-conductive yarns integrated therein. Manufacturing processes may include operations for electrically couplingone or more networks of insulated conductive yarns to provide circuit structures. It may be desirable to provide methods of selectively de-insulating portions of insulated conductive yarns whilst minimizing damage to conductive yarns and whilst efficiently scaling manufacturing processes for such textile bodies.

[0007] The present disclosure describes embodiments of methods of textile manufacturing including annealing operations for electrically coupling proximally located insulated conductive yarns at yarn engagement points. In some scenarios, engagement or contact points among the conductive yarns may include conductive fibers crossing over or under an adjacent conductive fiber at an intersection point.

[0008] In some embodiments, methods of such textile manufacturing for coupling at least one insulated conductive yarn with an adjacent conductive yarn may be based on operations that minimize or reduce operations for mechanically manipulating engagement or contact points among adjacent conductive yarns. For example, operations for coupling an insulated conductive yarn with an adjacent conductive yarn may be touchless and insulation of the insulated conductive yarn may remain in place. Embodiments described herein may provide operations for electrically coupling insulated yarns based on touchless and non-destructive methods.

[0009] In some embodiments, the methods of textile manufacturing may include tensioning operations for applying pressure across yarns to provide engagement points among interlaced fibers for downstream operations for electrically coupling insulated conductive yarns. Further features of embodiments will be described in the present disclosure.

[0010] In one aspect, the present disclosure describes a textile body. The textile body includes: a first conductive yarn including: a conductive fiber; and at least one coating layer surrounding the conductive fiber to form a composite conductive fiber; the at least one coating layer being a thermoplastic layer; and a second conductive yarn electrically coupled to the first conductive yarn at one or more engagement points, the one or more engagement points being encapsulated by one or more portions of the at least one coating layer.

[0011] In another aspect of the textile body, the at least one coating layer is a hydrophobic layer comprised of a hydrophobic polymer.

[0012] In another aspect of the textile body, the first conductive yarn further includes a hydrophobic layer comprised of a hydrophobic polymer.

[0013] In yet another aspect of the textile body, the hydrophobic layer comprises a hydrophobic polymer selected from a group consisting of styrene copolymers, vinyl chloride and vinyl acetate copolymers, and polyvinylidene fluoride copolymers.

[0014] In another aspect of the textile body, the hydrophobic layer includes a mixture of a hydrophobic polymer and a carbon black material circumferentially surrounding the first conductive fiber.

[0015] In another aspect of the textile body, hydrophobic layer is a composition including from about 1 to about 20 weight percent of the carbon black material.

[0016] In a still other aspect of the textile body, the hydrophobic layer circumferentially surrounding the first conductive fiber includes a mixture of a conductive carbon material and a hydrophobic polymer selected from the group of a polystyrene-block-poly(ethylene-ran-butylene- block-polystyrene-graft-maleic anhydride (SEBS-g-MA), a terpolymer comprised of vinyl chloride, vinyl acetate and maleic acid (VMCH), and a poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP).

[0017] In another aspect of the textile body, the thermoplastic layer comprises a thermoplastic polyurethane (TPU) or poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP).

[0018] In another aspect of the textile body, the thermoplastic layer includes a mixture of a polycarbonate-based thermoplastic polyurethane and a polyester-based thermoplastic polyurethane.

[0019] In yet another aspect of the textile body, the ratio of polyester-based thermoplastic polyurethane and polycarbonate-based thermoplastic polyurethane is from about 20:80 to about 80:20.

[0020] In a still other aspect of the textile body, the thermoplastic layer is a composition including a wax additive at a loading ranging from about 1 to about 5 weight percents.

[0021] In another aspect of the textile body, the one or more engagement points are encapsulated by one or more portions of the at least one coating layer using layer using an annealing operation including heating a region proximal to the one or more engagement points at a temperature within a range of about 100 degrees Celsius to about 160 degrees Celsius.

[0022] In another aspect of the textile body, the one or more engagement points are based on at least one of knitted, weaving, or embroidered structures.

[0023] In a still other aspect of the invention, the first conductive yarn includes at least one of metalized polymer yarns, hybrid conductive yarns, or conductive polymer yarns.

[0024] In another aspect, the present disclosure provides a method of producing a textile body comprising: a) constructing the textile body including a first conductive yarn and a second conductive yarn interlaced with the first conductive yarn at one or more engagement points, wherein the first conductive yarn includes a conductive fiber and at least one coating layer surrounding the conductive fiber to form a composite conductive fiber, the at least one coating layer being a thermoplastic layer; b) conducting one or more annealing operations to direct heat proximal to the one or more engagement points to electrically couple the first conductive yarn and the second conductive yarn by increasing the temperature of the thermoplastic layer to near its melting point at the one or more engagement points; and c) cooling the textile body to encapsulate the one or more engagement points with a the one or more coating layers.

[0025] In another aspect of the method, the at least one coating layer is a hydrophobic layer comprised of a hydrophobic polymer.

[0026] In a still other aspect, the method includes formulating the composite conductive fiber using a hydrophobic polymer selected from a group consisting of styrene copolymers, vinyl chloride and vinyl acetate copolymers, and polyvinylidene fluoride copolymers.

[0027] In yet another aspect, the method includes formulating the composite conductive fiber using a mixture of a hydrophobic polymer and a carbon black material circumferentially surrounding the first conductive fiber.

[0028] In a still other aspect, the method includes formulating the composite conductive fiber using about 1 to 20 percent carbon black material.

[0029] In yet another aspect of the method, the one or more annealing operations includes directing heat to at least of the engagement points to a temperature within a range of about 100 degrees Celsius to 160 degrees Celsius for a threshold time duration.

[0030] In a still other aspect of the method, annealing the textile body includes modulating the heat directed to the one or more engagement points over the threshold time duration.

[0031] In another aspect, the method includes the further step of tensioning the first conductive yarn relative to the second conductive yarn to promote contact at the one more engagement points.

[0032] In yet another aspect of the method, constructing the textile body which includes the first conducting yarn and the second conductive yarn by flat knitting at least the first conductive yarn and the second conductive yarn.

[0033] In this respect, before explaining at least one embodiment in detail, it is to be understood that the embodiments are not limited in application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0034] Many further features and combinations thereof concerning embodiments described herein will appear to those skilled in the art following a reading of the present disclosure.DESCRIPTION OF THE FIGURES

[0035] In the figures, embodiments are illustrated by way of example. It is to be expressly understood that the description and figures are only for the purpose of illustration and as an aid to understanding.

[0036] Embodiments will now be described, by way of example only, with reference to the attached figures, wherein in the figures:

[0037] FIG. 1 illustrates a textile body, in accordance with an embodiment of the present disclosure;

[0038] FIG. 2 illustrates a textile body, in accordance with an embodiment of the present disclosure;

[0039] FIG. 3 illustrates a textile body, in accordance with an embodiment of the present disclosure;

[0040] FIG. 4 illustrates a scanning electron microscope (SEM) image of uninsulated silver yarn, in accordance with embodiments of the present disclosure;

[0041] FIG. 5 illustrates SEM images of insulated silver yarns, in accordance with embodiments of the present disclosure;

[0042] FIG. 6 illustrates a textile electrode integrated on a textile body, in accordance with an embodiment of the present disclosure;

[0043] FIG. 7 illustrates a schematic view of the textile electrode of FIG. 6;

[0044] FIG. 8 illustrates a plan view of a textile garment, in accordance with an embodiment of the present disclosure;

[0045] FIG. 9 illustrates a schematic view of a textile garment, in accordance with embodiments of the present disclosure;

[0046] FIG. 10 illustrates an enlarged plan view of a portion of a knitted textile structure, in accordance with embodiments of the present disclosure;

[0047] FIG. 11 illustrates a textile garment, in accordance with embodiments of the present disclosure;

[0048] FIG. 12 illustrates a flowchart of a method of assembling a textile body, in accordance with an embodiment of the present disclosure;

[0049] FIG. 13 illustrates SEM images showing magnified views of a portion of a textile body, in accordance with embodiments of the present disclosure;

[0050] FIG. 14 illustrates a plan view of a textile electrode, in accordance with embodiments of the present disclosure;

[0051] FIG. 15 illustrates an enlarged first cross-sectional image and a second cross- sectional image of the textile electrode of FIG. 14;

[0052] FIG. 16 illustrates a scanning electron microscope image of a coated conductive yarn, in accordance with embodiments of the present disclosure;

[0053] FIG. 17 illustrates cross-sectional SEM images of coated conductive yarns, in accordance with embodiments of the present disclosure;

[0054] FIG. 18 illustrates a chart showing resistance measurement values of a trace band over washing, in accordance with an embodiment of the present disclosure;

[0055] FIG. 19 illustrates a chart showing resistance measurement values of a trace band over washing, in accordance with an embodiment of the present disclosure;

[0056] FIG. 20 illustrates example ECG measurement data of a user obtained using a textile electrode of a prototype textile garment, in accordance with an embodiment of the present disclosure;

[0057] FIG. 21 illustrates example ECG measurement data of a user obtained using a textile electrode of a prototype textile garment, in accordance with an embodiment of the present disclosure; and

[0058] FIG. 22 illustrates a flowchart of a method of producing a textile garment, in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0059] The present disclosure describes embodiments of textiles including conductive yarns integrated therein. Embodiments of textiles may be configured for textile computing systems.

[0060] The present disclosure describes embodiments of textiles and methods of textile manufacturing including annealing operations for electrically coupling proximally located insulated conductive yarns at yarn engagement points. Engagement or contact points among the conductive yarns may include conductive fibers crossing over, under, or around at an intersection point. Operations for coupling an insulated conductive yarn with an adjacent conductive yarn may be touchless and non-destructive. Further upon completion of annealing operations for coupling insulated conductive yarns with adjacent conductive yarns, insulative materials of the insulated conductive yarn remain in place.

[0061] Textiles including conductive yarns integrated therein may be configured to provide sensing devices or actuating devices, among other circuit structures. For example, textiles having conductive yarns configured as a sensing device may generate signals representing physiological data of a user. For instance, physiological data may include electrocardiogram data, skin conductance data, among other types of physiological data.

[0062] In another example, textiles having conductive yarns may be configured as an actuating device may generate signals for providing feedback to a user. For instance, actuating device signals may provide neurostimulation to a user, haptic feedback to a user, among other types of feedback signals to a user.

[0063] In some embodiments, textiles including conductive yarns integrated thereon may be configured as textile garments having electrically conductive circuits, sensor devices, actuator devices, or other types of data acquisition or feedback components. Textile garments may include shirts, pants, undergarments, chest bands, among other garments that may be donned by a user.

[0064] Electrically conductive paths or structures may be integrated into textiles by one or a combination of methods including inlaying, knitting, weaving, embroidery, adhesive bonding, or mechanical bonding. Other methods of integrating conductive paths into textile structures may be used.

[0065] In some examples, electrical, mechanical, or electro-mechanical fibers, such as piezoelectric, electromagnetic, shape shifting, or other types of yarns may be knitted or weaved into a textile fabric. For instance, electro-mechanical yarn may be knitted or weaved in a “zig-zag” pattern across textile fabric to provide sensor or actuator structures.

[0066] In some embodiments, a textile body may include a plurality of conductive fibers interlaced with a plurality of non-conductive fibers. The conductive fibers may define a plurality of signal paths suitable for delivering data or power to form a conductive fiber network. In some embodiments, the textile body may be formed of other textile forms or techniques such as weaving, knitting (warp, weft, etc.), among examples. In some embodiments, textile body may include any one of a knitted textile, a woven textile, a cut and sewn textile, a knitted fabric, a nonknitted fabric, in a combination or permutation thereof.

[0067] In some embodiments, interlaced fibers may include fibers crossing over and / or under one another in a predetermined configuration, such as alternately over and under one another in textile a layer. When interlaced, adjacent fibers may contact each other at engagement or intersection points (e.g. points where one fiber crosses over or under another fiber). In some examples, first fibers extending in a first direction can be interlaced with second fibers extending laterally or transverse to the fibers extending in the first direction. Interlaced fibers extending in a textile body may be referred to as a network of fibers.

[0068] As used herein “integrated” or “integrally” may refer to combining, coordinating, or otherwise bringing together separate elements to provide a harmonious, consistent, interrelated whole. A textile may include various sections including networks of fibers with varying structural properties. In some examples, a textile body may have a section comprising a network of conductive fibers and a section comprising a network of non-conductive fibers. Two or more sections comprising networks of fibers may be “integrated” together into a textile (or “integrally formed”) when at least one fiber of one network is interlaced with at least one fiber of the other network such that the two networks form a layer of the textile. In some examples, when integrated, two sections of a textile may also be described as substantially inseparable from the textile. “Substantially inseparable” refers to the notion that separation of the sections of the textile body from each other results in disassembly or destruction of the textile body itself.

[0069] In some examples, conductive fabric (e.g. group of conductive fibers) can be knit along with (e.g. to be integral with) the base fabric (e.g. surface) in a layer. Such knitting may be performed using a circular knit machine or a flatbed knit machine, warp knit, or the like, from a vendor such as Santoni, Stoll, or Karl Mayer.

[0070] In some description herein of embodiments, the terms fiber or yarn may be used interchangeably.

[0071] FIG. 1 illustrates a textile body 100, in accordance with an embodiment of the present disclosure. The textile body 100 may include one or more courses and wales for forming a knitted structure. The textile body 100 may be manufactured based on operations of one or a combination of flatbed knitting apparatus 110 or circular knitting apparatus 120.

[0072] FIG. 2 illustrates a textile body 200, in accordance with an embodiment of the present disclosure. The textile body 200 may include one or more warps and wefts for forming a woven structure. The textile body 200 may be manufactured based on operations of a Jacquard weaving machine 210.

[0073] FIG. 3 illustrates a textile body 300, in accordance with an embodiment of the present disclosure. The textile body 300 may include a substrate fabric 302 and embroidered yarn 304 embroidered therein for forming an embroidered structure. The textile body 300 may be manufactured based on operations of a multi-head embroidery machine 310.

[0074] In some examples, a textile body may refer to material made or formed by manipulating natural or artificial fibers to interlace to create an organized network of fibers. Textiles may be formed using yarn. Yarn may be a continuous length of a plurality of fibers that have been interlocked (i.e. fitting into each other, as if twined together, or twisted together). In some examples, the terms fiber or yarn may be used interchangeably. Fibers or yarns may be manipulated to form a textile according to a method that provides an interlaced organized network of fibers, including but not limited to weaving, knitting, sew and cut, crocheting, knotting and felting.

[0075] Various sections of a textile may be integrally formed into a layer to utilize different structural properties of fiber types. For example, conductive fibers may be configured to form networks of conductive fibers, and non-conductive fibers can be configured to form networks of non-conductive fibers. These networks of fibers can comprise different sections of a textile by integrating the networks of fibers into a layer of the textile. The networks of conductive fibers may form one or more conductive pathways that electrically connect with sensor devices or actuator devices embedded in a textile body. In some embodiments, sensor devices or actuator devices may be configured as textile electrodes. Multiple layers of textile can also be stacked upon each other to provide a multi-layer textile.

[0076] In some embodiments, conductive yarns for textile computing platforms may be selected based on at least one of electrical, mechanical, or other functional properties. In some examples, conductive yarns may be metalized polymer yarns, hybrid conductive yarns, or conductive polymer yarns, among other examples.

[0077] In some embodiments, metalized polymer yarns may include a plurality of metalized polymer fibers, such as silver-plated nylon fibers or other metal-coated polymer fibers or filaments. In some embodiments, insulated conductive yarns may be silver-plated nylon yarns having a thermoplastic polyurethane (TPU) coating thereon.

[0078] In some embodiments, hybrid conductive yarns may include a plurality of polymer fibers in combination with conductive metal wires. Polymer fibers may be based on polyester or polyamide materials. Conductive metal wires may include stainless steel, copper, brass, nickel, or metal alloys.

[0079] In some embodiments, conductive polymer yarns may include polymer fibers or filaments including a surface coating or a filler of conductive materials, including conductivepolymers, conductive carbon particles, carbon nanotubes, graphene, conductive metal oxide particles, among other example conductive materials. In some examples, carbon electrodes may be based on carbon-containing nylon yarns.

[0080] In some embodiments, textile computing systems may include textiles having non- conductive yarns. For example, textile base layers may include non-conductive yarns such as synthetic fibers based on polyesters or polyamides (nylon) or natural fibers such as cotton, silk, among other examples.

[0081] Reference is made to FIG. 4, which is a scanning electron microscope (SEM) image 400 of uninsulated silver yarn, in accordance with embodiments of the present disclosure. The uninsulated silver yarn includes a plurality of silver-plated nylon fibers twisted as a bundle.

[0082] Reference is made to FIG. 5, which illustrates SEM images of insulated silver yarns, in accordance with embodiments of the present disclosure. A first SEM image 502 illustrates the insulated silver yarn having a coating covering the circumferential surfaces of the silver yarn.

[0083] A second SEM image 504 illustrates a cross-sectional view of the insulated silver yarn, showing a twisted bundle of the plurality of silver yarns having a coating covering a circumferential surface of the twisted bundle.

[0084] Conductive traces may be configured to interconnect a plurality of circuit components integrated into a textile body, including sensors, actuators, heating components, optoelectronics, data recording devices, electronic controllers, or power devices. Merely for illustration, examples of textile-based computing platforms may be shown in US patent application publication number US 2021 / 0204877. Further, examples of electrocardiogram (ECG) sensor systems may be shown in US patent application publication number US 2023 / 0123028.

[0085] As described, a plurality of conductive yarns integrated with a textile body may be configured to form a data or power for circuit devices. The conductive yarn may have prior- selected electrical or mechanical properties for forming circuit devices or transmission lines. Prior- selected properties may include electrical conductivity, yarn malleability or mechanical strength, among other properties.

[0086] In scenarios where the conductive yarn may be uninsulated, the electrical or mechanical properties may deteriorate over time due to textile washing, due to exposure to environmental fluids (e.g., chemical treatments or user bodily fluids, etc.), or due to mechanicalcontact with neighboring materials. It may be desirable to provide a protective layer for the conductive yarns for maintaining the integrity or prior-selected characteristics of the conductive yarns.

[0087] Respective conductive yarns integrated with a textile body may be proximal to another conductive yarn. In scenarios where the textile body may be exposed to bodily fluids, such as perspiration, proximal conductive yarns may electrically short circuit in an unintended way. It may be desirable to provide insulated conductive yarns for reducing the likelihood of electrical short circuits among proximal conductive yarns associated with a network of conductive yarns.

[0088] In some embodiments, a textile body may be manufactured based on operations of a knitting apparatus, a weaving apparatus, or an embroidery apparatus, among other example apparatus. Manufacturing operations may include operations for pre-tensioning or applying pressure to yarns during knitting, weaving, or embroidery operations. In some scenarios, there may be a plurality of forces applied to respective yarns during knitting, weaving, or embroidery operations. As such, the integral structure of a textile body may contribute to respective textile yarns experiencing one or more tension forces at an intersection location with other textile yarns. In embodiments where conductive yarns may be insulated or otherwise coated, it may be desirable to provide an insulative coating that retains the pre-selected properties of the insulative coating and the conductive yarns themselves upon experiencing a plurality of applied forces during textile body manufacturing.

[0089] In some scenarios, methods of manufacturing textiles having integrated conductive fibers may include operations for coupling adjacent conductive fibers at engagement points or interfaces. In some examples, methods for electrically coupling insulated conductive yarns with adjacent conductive yarns or conductive substrates may include operations for removing insulative coatings based on solvents for stripping coatings or laser-based operations for abrading coatings. In some other examples, methods for electrically coupling insulative conductive yarns may include ultrasonic welding for localized melting of insulative coatings of conductive yarns. These example methods may contribute to physical damage to the underlying conductive yarns or textile bodies.

[0090] As an example, ultrasonic welding operations may include operations based on a nearfield ultrasonic welding 8 mm threaded horn configured to provide 20 pounds per square inch (PSI) of pressure, an amplitude of 50 units, with a hold time of 2 to 3 seconds, and a weld time of0.1 to 0.3 seconds. When melting TPU coatings based on example ultrasonic welding operations, insulated silver-plated nylon yarns may be broken. When utilizing ultrasonic welding operations, it may be challenging for operations to delineate TPU coating material and silver-coated nylon, thereby resulting in an uncontrolled melting of both coating material and nylon material.

[0091] It may be desirable to provide methods of textile manufacturing for coupling at least one insulated conductive yarn with an adjacent conductive yarn such that the conductive fibers remain insulated by the coatings forming the insulation after application of the method of coupling.

[0092] Reference is made to FIG. 6, which illustrates a textile electrode 610 integrated on a textile body, in accordance with embodiments of the present disclosure. As an example, the textile electrode 610 may be a carbon electrode having a plurality of carbon yarns interconnected and physically configured as a network for sensing bio-signal data of a garment user.

[0093] In FIG. 6, the textile body may include a plurality of interlaced textile layers. A base layer may be knitted to include non-conductive yarns. A user-facing layer of the textile electrode 610 may include a plurality of coupled conductive carbon yarns. Further, one or more trace yarns 620 may be interlaced and electrically coupled with the carbon yarns.

[0094] The one or more trace yarns 620 may be a different conductive material than the conductive carbon yarn. The conductive carbon yarn may be adeptly suitable for detecting biosignal data of the garment user but may have relatively high electrical resistivity. The relatively high electrical resistive properties of carbon yarn may make it unsuitable as a transmission line for transmitting electrical signals to other electrical devices or structures. Accordingly, the one or more trace yarns 620 having relatively lower electrical resistivity may be electrically coupled with the conductive carbon yarn and may be routed to an interconnection zone or electrical pad 630. The electrical pad 630 may be configured to couple a computing device or other circuit with the textile electrode 610. In some embodiments, the trace yarns 620 may be silver-plated nylon yarn, among other examples.

[0095] As will be described herein, in some embodiments, the one or more trace yarns 620 may be insulated with an insulative coating material. The insulative coating may be configured to provide protection from mechanical abrasion, to reduce likelihood of unintended electrical shorts among proximally located conductive fibers, or to reduce leaching of metal components when the conductive materials may be wetted or moist based on use by a garment user.

[0096] Methods of providing an interconnection among proximally located conductive yarns, such as between an insulated conductive yarn (e.g., trace yarn 620) and an adjacent conductive yarn (e.g., carbon yarn of the textile electrode 610) will be described in the present disclosure.

[0097] Reference is made to FIG. 7, which illustrates a schematic view of the textile electrode 610 of FIG. 6 integrated in the textile body. As described, the trace yarn 620 may include a second type of conducting yarn material (e.g., silver yarn, among examples) that may be different than the representative carbon yarn material of the textile electrode 610.

[0098] In some embodiments, the trace yarn 620 may be silver-plated nylon yarn (e.g., Silver 53) may be knitted fibers of the textile electrode 610. As will be described, in some embodiments, operations may be conducted for de-insulating the trace yarn 620 to electrically couple the trace yarn 620 and the knitted fibers of the textile electrode 610.

[0099] Some scenarios, operations may similarly be conducted for de-insulating the trace yarn 620 proximal to the electrical pad 630 to electrically couple the trace yarn 620 and the electrical pad 630

[0100] Reference is made to FIG. 8, which illustrates a plan view of a textile garment 800, in accordance with embodiments of the present disclosure. The textile garment 800 may be a textile chest band including one or a plurality of textile electrodes 810 integrated thereon. In FIG. 8, a pair of textile garments 800 is shown. In some embodiments, the textile electrodes 810 may be configured as data acquisition or sensor devices. In some embodiments, the textile electrodes 810 may be configured as actuating devices configured to provide feedback stimulus to a user.

[0101] In some embodiments, the textile electrodes 810 may include a non-conductive textile body with conductive yarns integrated therein for forming the textile garment 800. In some embodiments, one or more textile electrodes 810 may be electrically coupled via conductive yarns integrated within a non-conductive textile body. In some embodiments, one or more textile electrodes 810 may be electrically coupled via conductive yarns to an electrical pad or interconnection zone for coupling to other electronic devices.

[0102] Reference is made to FIG. 9, which illustrates a schematic view of a textile garment 900, in accordance with embodiments of the present disclosure. The textile garment 900 may include one or more electrodes 910. Respective electrodes 910 may be coupled to an electrical pad 930 via a conductive yarn traces 920.

[0103] Two or more conductive yarn traces 920 may be integrated with a textile body of the textile garment 900. In some situations, respective conductive yarn traces 920 may be proximal another conductive yarn trace 920 such that uninsulated conductive yarns that are proximal other uninsulated conductive yarns may be electrically short circuit in an unintended way. Proximal uninsulated conductive yarns may experience a higher likelihood of electrically shorting to one another when exposed to environmental elements or bodily fluids, such as perspiration, of a garment user. It may be desirable to provide insulated conductive yarns for reducing a likelihood of electrical short circuits among proximal conductive yarns associated with a network of conductive yarns.

[0104] The present disclosure describes embodiments of textile bodies including insulated conductive fibers. In some embodiments, the insulated conductive fibers may be thermoplastic polyurethane (TPU) coated conductive yarn integrated in a textile body, and the insulated conductive fibers may be configured in a circuit network. In some examples, the insulation or coating may be polycarbonate-based polyurethane or polyester-based polyurethane. As an example, insulated conductive yarns may be coated with a polyurethane outer layer, such as a polyester-based polyurethane or a polycarbonate-based polyurethane.

[0105] In some scenarios of textile manufacturing, conductive and non-conductive yarns may respectively experience tensioning forces from a plurality of directions. Such tensioning forces may mechanically stress the yarns during textile body manufacturing. It may be desirable to provide insulated conductive yarns with insulative coatings that can withstand tensioning forces during textile manufacturing.

[0106] In some embodiments of textiles based on the invention, TPU-615™ coated conductive yarns supplied by Alberingk Boley Inc. may be used. Using TPU-615, no appreciable damage or fatigue was observed to the TPU-615 coated conductive yarns during or after textile manufacturing as described. It may be appreciated that other types of insulative coatings for insulating conductive yarns may be used.

[0107] Reference is made to FIG. 10, which illustrates an enlarged plan view of a portion of a knitted textile structure 1000, in accordance with embodiments of the present disclosure. The knitted structure 1000 includes a plurality of yarns configured as courses and wales.

[0108] The knitted textile structure 1000 may be illustrative of a textile electrode including a base layer, an interconnective layer, and a user-facing layer. The base layer may include non- conductive yarn 1010 for providing a textile base for the textile electrode.

[0109] The user-facing layer may include carbon-based yarn 1020 configured to contact a garment user’s skin. The carbon-based yarn may have desirable sensing capabilities for detecting or generating bio-signal data of the garment user. In some examples, carbon-based yarn may have relatively high electrical resistivity, thereby impeding carbon-based yarn as a suitable electrical transmission line for interconnecting electrical circuits.

[0110] In some embodiments, the interconnective layer may include conductive yarn 1030 with relatively low electrical resistivity thereby being suitable as an electrical transmission line for interconnecting electrical circuits. In some embodiments, the conductive yarn 1030 may be silverbased yarn. The conductive yarn 1030 may be interlaced and thereby electrically coupled to the carbon-based yarn 1020 for providing an electrical transmission line between the carbon-based yarn 1020 and a downstream electrical pad or electronic device.

[0111] Further, the conductive yarn 1030 may be interlaced with the non-conductive yarn 1010, which forms the textile base layer. As described herein, it may be desirable that the conductive yarn 1030 be coated with an insulative material to address one or more challenges of utilizing an uninsulated conductive yarn in a textile body.

[0112] In some embodiments, the conductive yarn 1030 may be a TPU-coated conductive yarn. As the TPU-coated conductive yarn may electrically insulate the conductive yarn 1030 from proximal yarns or adjacent yarns (e.g., carbon-based yarn 1020), it may be desirable to provide methods of textile manufacturing for electrically coupling the conductive yarn 1030 to proximal or adjacent yarns for providing electrical circuits within textile garments. As will be described, methods of textile manufacturing for electrically coupling the conductive yarn 1030 with the carbon-based yarn 1020 at the yarn interface 1040 without altering or damaging the knitted network of yarns may be desirable.

[0113] In the present example, mechanically removing TPU-coating from the TPU-coated conductive yarn 1030 to provide electrical contact may not be practically feasible given the diameter of the respective yarns. Removing TPU-coating material based on solvent stripping operations or laser abrasion operations may result in damage to the knitted yarn network or mayresult in unintended TPU-coating damage along portions of yarn where the TPU-coating may be desirable.

[0114] In another scenario, removing TPU-coating material based on ultrasonic welding may include localized melting operations of TPU-coated conductive yarn. However, ultrasonic welding operations may cause unintended melting or damage to yarns at knit locations distal from the yarn interface 1040.

[0115] In some situations, mechanically or chemically removing TPU-coatings from conductive fibers may be cumbersome, prone to error, prone to yarn damage, or may be inefficient or impractical during manufacturing processes of textile bodies.

[0116] It may be desirable to provide operations for selectively coupling conductive yarns at the yarn interface 1040 and without altering the integrity of an insulative coating from other portions of yarns distal from the yarn interface 1040. It may be desirable to provide operations for selectively coupling conductive yarns at the yarn interface 1040 such that an insulative coating may protect the yarn interface 1040 upon completion of embodiments of the textile manufacturing operations. In addition, it may be desirable to provide operations for selectively coupling conductive yarns based on a process that may be integrated with textile manufacturing apparatus and scaled for large volume production.

[0117] The various mixtures of TPLIs described in this disclosure are examples only. Many other mixtures are possible, and various other materials may be suitable, and indeed can be selected based on material characteristics and other features such as ability to tune the formulation or manufacturing requirements such as (and not limited to) annealing temperature or annealing time, as well as various physical properties of the resulting textile body (or product made of the fiber such as a garment) including washability, tackiness, etc. As this disclosure describes, using the textile body and method for producing a textile body described, various physical properties are tunable.

[0118] Reference is made to FIG. 11 , which illustrates a textile garment 1100, in accordance with embodiments of the present disclosure. The textile garment 1100 may be a knitted garment including carbon-based yarn 1120 and TPU-coated conductive yarn 1130 interlaced therewith.

[0119] FIG. 11 illustrates a 20X magnification enlarged image 1102 illustrating the interlacing structure of carbon-based yarn 1120 and TPU-coated conductive yarn 1130. FIG. 11 furtherillustrates a 100X magnification enlarged image 1104 illustrating the interlacing structure of carbon-based yarn 1120 and TPU-coated conductive yarn 1130. Due to the intricate detail of the knit structure, it may be infeasible to selectively remove portions of the TPU coating from the TPU- coated conductive yarn 1130 for electrically coupling to the carbon-based yarn 1120. Further, solvent-based solutions or ultra-sonic-based operations for removing portions of the TPU coating from the TPU-coated conductive yarn 1130 may result in underlying physical damage to the yarns.

[0120] Reference is made to FIG. 12, which illustrates a flowchart of a method 1200 of assembling a textile body, in accordance with embodiments of the present disclosure. The method 1200 may be conducted by one or more textile manufacturing apparatus in combination with an integral or downstream annealing process for electrically coupling insulated conductive yarns interlaced in textile bodies.

[0121] At operation 1202, the apparatus may construct the textile body including non- conductive yarns and conductive yarns. In some embodiments, the conductive yarns may be integrated with the non-conductive yarns to provide a data or power network for coupling two or more electronic circuits associated with the textile body.

[0122] In some embodiments, the apparatus may be a flatbed knitting (for flat knitting) or circular knitting apparatus for producing knitted textile structures 100 (FIG. 1). In some embodiments, the apparatus may be a jacquard weaving machine 210 for producing woven textile structures 200 (FIG. 2). In some embodiments, the apparatus may be a multi-head embroidery machine 310 for producing embroidered textile structures 300 (FIG. 3).

[0123] At operation 1202, embodiments of the textile manufacturing apparatus may be configured to interlace insulated conductive yarns within the constructed textile body. In some embodiments, the insulated conductive yarns may be insulated silver yarns, insulated silver- coated nylon yarns, insulated copper yarns, insulated carbon yarns, or other types of insulated conductive yarns for forming a conductive yarn network within the constructed textile body.

[0124] In some embodiments, the insulative coating may be a suitable thermoplastic polyurethane such as for example the TPU-615 coating. In textile manufacturing test operations, when conductive yarns are insulated with thermoplastic polyurethane coatings, the physical integrity of such TPU-615 coated conductive yarns may be substantially maintained whilst being subjected to a plurality of tensioning operations during textile manufacturing. Embodiments of thermoplastic polyurethane coatings may be configured to prolong the physical integrity of theconductive yarns during textile manufacturing or during exposure to environmental elements (e.g., textile washing, chemical treatments, user bodily fluids, mechanical contact with neighboring materials, etc.).

[0125] At operation 1204, the textile manufacturing apparatus may conduct one or more annealing operations on the constructed textile body. The annealing operations may be configured to electrically couple conductive textile yarns at a yarn interface. The yarn interface may include at least one conductive textile yarn having an insulative coating surrounding a circumferential surface of the textile yarn.

[0126] In some embodiments, the annealing operation at operation 1204 may be conducted at a temperature such that the respective insulative coating may deform in response to applied tension or stresses at one or more engagement or contact points among the conductive yarns.

[0127] To illustrate, the insulative conductive yarn may be coated with a thermoplastic polyurethane coating. Operations for providing the heat treatment may cause the thermoplastic polyurethane coating at the yarn interface to deform thereby promulgating electrical coupling at one or more engagement or contact points among the conductive yarns.

[0128] In the example described above, the thermoplastic polyurethane coating may melt or partially melt at a suitable melting temperature, which for some thermoplastic polyurethane coatings is generally approximately 100 degrees Celsius to about 160 degrees. Example annealing operations for subjecting the constructed textile body to the melting temperature environment described, may cause the thermoplastic polyurethane coating to deform, thereby facilitating insulated conductive yarns in physical contact to become electrically coupled. The annealing operation, in one embodiment, can be conducted by direct heating one or more regions proximal to the one or more engagement points. The direct heating temperature in one embodiment is within a range of 100 degrees Celsius to about 160 degrees Celsius. In another embodiment, the direct heating temperature is within a range of 100 degrees Celsius to 140 degrees Celsius.

[0129] In one aspect of the invention, a textile body is formed by applying annealing operations to a to an ag

[0130] Referring again to FIG. 10, annealing operations may cause portions of thermoplastic polyurethane coating of the conductive yarn 1030 to melt or otherwise deform, thereby promotingelectrical contact among the conductive yarn 1030 and adjacent carbon-based yarn 1020 at the yarn interface 1040.

[0131] In some embodiments, the annealing operations may be configured based on physical or rheological characteristics of insulative coatings. For example, if variants of thermoplastic polyurethane coatings or polymer coatings are configured for insulating conductive yarns, the annealing operations may be configured to provide a heating environment that may be greater than or less than 160 degrees Celsius based on the rheological characteristics of the respective insulative coatings. In some scenarios, the temperature for the annealing operations may be lower than a melting temperature of the base yarns for avoiding physical damage to textile bodies.

[0132] In some embodiments, the annealing operations may include modulating or otherwise controlling the change in the temperature of the constructed textile to promote melting or deforming of the insulative coating for electrically coupling proximal conductive yarns. For example, the annealing operations may include controlling the change in temperature of the constructed textile body when approaching the melting point of the target insulative coating.

[0133] In another example, the annealing operations may include modulating the temperature at the constructed textile body to iteratively promote melting or deforming of the insulative coatings at points of contact among conductive yarns. For example, operations for modulating the temperature may include controlling the temperature based on a sinusoidal profile having a predefined heating period.

[0134] In some embodiments, the annealing operations may include controlling the decline in temperature of the constructed textile body towards a latter portion of the annealing operations to ensure that insulative coatings may retain their position about the circumferential surface of the conductive yarns. The annealing operations as disclosed can also be described as resulting in the encapsulation of the constructed textile body such that the yarn engagement points are still covered with insulation after the annealing is completed. This disclosure at various points refers to “coating” and / or “coating layers”, which may also be described as “encapsulating” or “encapsulating layers” to reflect that in one aspect of the invention the engagement points will remain covered with insulation after annealing is completed.

[0135] In some scenarios, the annealing operations may include tensioning or otherwise stretching in one or more directions the constructed textile body for promoting physical contact at respective yarn interfaces 1040 (FIG. 10) among insulated conductive yarns. By promotingphysical contact at the intersection of insulated conductive yarns, operations for assembling the textile body may provide for electrical coupling efficiency from melting or otherwise dissolving of the insulative coatings at contact points of the respective yarn interfaces 830.

[0136] At operation 1206, the textile manufacturing operations may include cooling the constructed textile body for setting the insulative coating at the electrically coupled contact points at the yarn interface 1040 (FIG. 10) and for setting the insulative coating at portions of the conductive yarn distal from the electrical coupling contact points.

[0137] Referring again to FIG. 7, to assess the efficacy of embodiments of annealing operations for electrically coupling proximally positioned insulated conductive yarns, resistance measurements may be conducted for comparing: (1) resistance prior to the annealing operations of operation 1204 (FIG. 12); and (2) after the annealing operations 1204.

[0138] To illustrate, resistance measurements were made to an embodiment of the textile garment 600 similar to that illustrated in FIG. 6. Impedance measurements were made to a prototype textile garment both prior to conducting annealing operations to the textile garment 600. In an example, resistance measurements were made between the representative carbon-based yarn 610 (e.g., carbon electrode) and the downstream electrical pad 630 for evaluating the efficacy of electrically coupling the carbon yarn 610 and the yarn at the electrical pad 630. In scenarios where resistance measurements and testing operations are conducted, the insulative coating is removed from yarns of the electrical pad 630. In a test, the observed resistance values are summarized in Table 1.

[0139] Table 1 : Experiment data illustrating measured resistance prior to and after annealing operations of FIG. 12 on an embodiment of the textile garment 600 of FIG. 6.

[0140] Table 1 shows that embodiments of annealing operations disclosed in the present disclosure may be suitable for electrically coupling proximally positioned insulated conductive yarns at contact points of a yarn interface. As the resistance measurements have decreased by several orders of magnitude, embodiments of the annealing operations may be effective for electrically coupling insulated conductive yarns at contact points of a yarn interface while maintaining insulative coatings along other circumferential portions of the conductive yarn. For example, the annealing operations associated with the resistance measurements shown in Table 1 include subjecting a textile body to heat treatment in an oven at 160 degrees Celsius for 10 minutes for altering a state of the insulative coating at a yarn interface (where adjacent or overlapping conductive yarns may be positioned) to electrically couple the conductive yarns.

[0141] To assess the longevity of the electrical coupling of the conductive yarns in the abovedescribed example, the textile body was laundered for at least two cycles. Continuing with the above-described example, resistance measurements at the same reference points provided repeatable measurements of 3 to 5 kQ, thereby illustrating that the annealing operations of the present disclosure provide for electrical coupling of conductive yarns having insulative coatings.

[0142] Referring again to FIG. 9, to assess the efficacy of embodiments of annealing operations for electrically coupling proximally positioned insulated conductive yarns, resistance measurements were made for comparing: (1) resistance prior to the annealing operations of operation 1204 (FIG. 12); and (2) after the annealing operations 1204 (FIG. 12).

[0143] In FIG. 9, resistance measurements may be made between the respective electrodes 910 and a corresponding electrical pad 930. In a validation test, Table 2 illustrates resistance values that were observed both prior to and after embodiments of annealing operations 1204 of FIG. 12.

[0144] Table 2: Experimental data illustrating measured resistance prior to and after annealing operations of FIG. 12 on an embodiment of the textile garment 900

[0145] Table 2 illustrates the repeatability of electrically coupling proximally positioned insulated conductive yarns following embodiments of the annealing operations described in the present disclosure. To provide a baseline reference, it was observed that a prototype knitted with uninsulated silver yarn had a measured resistance of 3 to 4 kQ. Accordingly, prototype samples constructed with insulated conductive yarns and subjected to embodiments of annealing operations for coupling at least one insulated yarn to an adjacent yarn described in the present disclosure provided similar results as with prototype samples constructed with uninsulated yarns.

[0146] Reference is made to FIG. 13, which illustrates scanning electron microscope (SEM) images 1300 showing magnified views of a portion of a textile body, in accordance with embodiments of the present disclosure. A surface view image 1302 shows a section of the textile body at a yarn interface where carbon-based yarn may have been removed from the interface (shown at the dashed reference line).

[0147] A cross-sectional image 1304 illustrates a yarn interface illustrating that a portion of thermoplastic polyurethane-coating of a conductive yarn deformed from an annealing operation, thereby allowing silver-plated fibers of a bundle to couple or contact with carbon-based yarn providing an electrically coupled yarn interface. In the cross-sectional view image 1304, portions of the silver-plated fibers distal from the yarn interface may continue to be coated by thermoplastic polyurethane coating material.

[0148] In some embodiments, upon completion of cooling operations of the textile body, the thermoplastic polyurethane-based insulation coating may remain at the engagement or contact points where the respective conductive yarns interface with one another. The engagement points where yarns electrically couple may be insulated with the thermoplastic polyurethane-based insulation coating upon completion of the annealing operations.

[0149] Reference is made to FIG. 14, which illustrates a rear plan view of a textile electrode 1400, in accordance with embodiments of the present disclosure. The textile garment 1400 may be a garment having three-dimensional structure provided by two or more textile layers interlaced among one another. In some embodiments, a textile garment having a three-dimensional structure may include non-conductive materials integrated within the textile body to provide textile body shapes.

[0150] In some embodiments, one or a plurality of conductive yarn material types may be configured for providing textile sensor or textile actuator devices. As an example, FIG. 14 illustrates a textile electrode 1400 having a base layer including non-conductive yarn 1410 to form a textile base. The textile electrode 1400 may include a carbon-based yarn 1420 configured for interfacing with skin of a garment user. In some situations, carbon-based yarn 1420 may have properties suitable for detecting or generating, via the user skin, bio-signal data. However, carbonbased yarn 1420 may be less suitable as an electrical transmission line for transmitting electrical signals to a downstream electrical device due to relatively high resistivity of the carbon-based yarn 1420.

[0151] In some embodiments, the textile electrode 1400 may include a spacer yarn 1430 for structurally interconnecting the carbon-based yarn 1420 and the non-conductive yarn 1410. The spacer yarn 1430 may be configured to provide a three-dimensional structure or a raised structure for promoting user skin contact with the carbon-based yarn 1420.

[0152] In some embodiments, the spacer yarn 1430 may be an insulative-coated conductive yarn, such as thermoplastic polyurethane-coated silver-based yarn. The spacer yarn 1430 may be electrically coupled to the carbon-based yarn 1420 based on operations of textile manufacturing, including annealing operations. As silver-based yarn may have relatively lower electrical resistivity, the silver-based yarn configured as the spacer yarn 1430 may be adeptly configured as an electrical transmission line for coupling the carbon-based yarn 1410 with a downstream electronic device or other electrical device.

[0153] Reference is made to FIG. 15, which illustrates an enlarged first cross-sectional image 1502 and a second cross-sectional image 1504 of the textile electrode 1400 of FIG. 14. The spacer yarn 1430 may be insulated conductive yarn having relatively low resistivity and configured to be an electrical transmission line electrically coupling the carbon-based yarn 1420 with a downstream electrical device. As illustrated, the spacer yarn 1430 may also contribute to a three- dimensional structure to provide a raised textile electrode for interfacing skin of a garment user.

[0154] The non-conductive yarn 1410 may be configured as a textile base layer. In some configurations, the spacer yarn 1430 may be interlaced with the non-conductive yarn 1410 to the extent that the spacer yarn 1430 is configured to be routed as an electrical transmission line for coupling the carbon-based yarn 1420 and the downstream electrical device or circuit.

[0155] As illustrated in FIG. 15, the interlacing structure among the non-conductive yarn 1410, the carbon-based yarn 1420, and the spacer yarn 1430 may be intricate and a product of extensive knitting, weaving, or other textile manufacturing operations. It may be impractical to conduct solvent stripping operations, ultra-sonic welding operations, or other mechanical operations for selectively deforming or removing insulative coatings for coupling proximal or adjacent conductive yarns. Thus, operations of textile manufacturing including annealing operations described in the present disclosure may provide desired operations for touchless operations to deform insulative coatings among at least one insulated conductive yarn for electrically coupling adjacent conductive yarns and without damaging conductive yarns at a yarn interface.

[0156] Embodiments of the present disclosure include textile structures having carbon-based yarns and thermoplastic polyurethane-insulated conductive yarns, such as silver yarns. It may be appreciated that other combinations of conductive yarns where at least one conductive yarn type includes an insulative coating may be used. Embodiments of annealing operations for electrically coupling insulated conductive yarns may be configured based on specific rheological characteristics of respective insulative coatings.

[0157] In some embodiments described above, conductive yarns coated with thermoplastic polyurethane coatings such as TPU-615. Example annealing operations for softening or melting TPU-615 coated conductive yarns included annealing temperatures of approximately 160 degrees Celsius. In some scenarios, annealing temperatures of approximately 160 degrees Celsius may result in reduced adhesion of the thermoplastic polyurethane coatings to conductiveyarns. In some scenarios, where thermoplastic polyurethane coatings may not optimally adhere to conductive yarns, moisture ingress may lead to coating delamination from conductive yarns over time. Laundering of textile garments including thermoplastic coated conductive yarns may further promote delamination of coatings, thereby causing unintended increasing electrical resistivity of the conductive yarns over time. In some scenarios, it may be desirable to provide composite conductive yarn coatings to reduce occurrences of coating

[0158] Reference is made to FIG. 16, which illustrates a reel 1602 of coated conductive yarn, in accordance with embodiments of the present disclosure. As will be described, the conductive yarn may include a composite coating to provide a moisture barrier and to provide an abrasion resistant barrier whilst the conductive yarn is integrated in a textile body. FIG. 16 also illustrates a scanning electron microscope (SEM) image 1604 showing a magnification of coated conductive yarn, in accordance with embodiments of the present disclosure.

[0159] FIG. 17 illustrates cross-sectional SEM images 1702, 1704 of coated conductive yarns, in accordance with embodiments of the present disclosure. For example, a first cross- sectional SEM image 1702 shows a bundle of silver-coated yarns having a composite coating surrounding a circumferential surface of the bundle of silver-coated yarns.

[0160] A second cross-sectional SEM image 1704 shows a further magnified view of the composite coating surrounding a circumferential surface of the bundle of silver-coated yarns.

[0161] In some embodiments, the composite coating may include: (a) a hydrophobic composite coating surrounding the bundle of silver-coated yarns; in combination with (b) a thermoplastic polyurethane composite coating surrounding the hydrophobic-coated bundle of silver-coated yarns. Described embodiments reference silver-coated yarns for illustration, however other types of yarns may be treated with embodiments of composite coatings described herein.

[0162] In some embodiments, the hydrophobic composite coating may be a polystyrene- block-poly(ethylene-ran-butylene)-block-polystyrenbe-graft-maleic anhydride (SEBS-g-MA) layer surrounding a circumferential surface of the bundle of silver-coated yarns. The SEBS-g-MA layer may be a hydrophobic layer for insulating the bundle of silver-coated yarns. In some embodiments, the SEBS-g-MA layer may have rheological properties such that the material may melt or flow at a temperature that is lower than temperatures (e.g., 160 degrees Celsius) of TPU- 615 materials in earlier-described coating embodiments.

[0163] In some embodiments, the hydrophobic composite coating may include carbon black material. As an example, the carbon black material may be Vulcan-72 carbon black. Embodiments of the hydrophobic composite coating may be provided based on mixing SEBS-g-MA and Vulcan- 72 carbon black in toluene at specific lading ratios, followed by ball milling with stainless shots for 48 hours. In some scenarios, conductivity of the carbon black material may increase the conductive core diameter of the overall coated bundle of silver-yarns, thereby promoting increased heat activation reliability when coupling the coated bundle of silver-yarns with adjacent conductive yarns.

[0164] In some embodiments, the carbon black material may contribute to decreased tackiness of the bundle of silver-yarns for promoting manufacturability, including easier flow and handling during subsequent coating operations for adding thermoplastic layers.

[0165] As described above, the coated bundle of silver-yarns may additionally include a thermoplastic polyurethane composite coating surrounding the hydrophobic-coated bundle of silver-coated yarns. In some embodiments, the thermoplastic polyurethane composite coating may include a mixture of two or more suitable thermoplastic polyurethane materials. For example, the thermoplastic polyurethane composite coating may include: (i) a TPU-U5201 material in combination with (ii) a TPU-615 material, along with a wax dispersion. In some scenarios, the wax dispersion may reduce material tackiness and improve water resistance of the thermoplastic polyurethane materials.

[0166] In embodiments where the hydrophobic composite coating includes carbon black material, the hydrophobic composite may characteristically increase thermal conduction I transfer I distribution to the thermoplastic polyurethane composite coating. The present described combination of coatings may result in reduced time for the coating melting process.

[0167] As compared to a coating of primarily TPU-615 material (where a coating melting or activation temperature is approximately 160 degrees Celsius), coating the hydrophobic-coated bundle of silver-coated yarns with the combination of TPU-U5201 and TPU-615 material provides for a reduced coating melting or activation temperature and reduced activation time, thereby promoting increased manufacturability characteristics (e.g., reduced coating time, greater malleability, etc.).

[0168] In some embodiments, the thermoplastic coating dispersions may be produced based on a mixture of TPU-615, TPU-5201 and wax dispersion, followed by air stripping at 50 degrees Celsius to provide a viscosity suitable for yarn coating.

[0169] In the above-described embodiments including a combination of a hydrophobic composite coating and a composite TPU-coating surrounding a circumferential surface of the bundle of silver-coated yarn provides a desired balancing of desirable properties, including reduction of yarn tackiness, lower activation I melting temperature for electrically coupling adjacent or adjoining yarns, increased abrasion resistance, among other properties.

[0170] Referring again to FIG. 17, the second cross-sectional SEM image 1704 shows an example of the composite coating including a hydrophobic composite coating 1752 surrounding the bundle of silver-coated yarns and the thermoplastic polyurethane composite coating 1754 surrounding the hydrophobic-coated bundle of silver-coated yarns. In the illustrated example of the second cross-sectional SEM image 1704, the hydrophobic composite coating 1752 may be 18.5 urn thick and the thermoplastic polyurethane composite coating 1754 may be 14.6 urn. Other coating thicknesses may be contemplated.

[0171] The thickness of the hydrophobic composite coating may range from about 1 to about 25 microns, while the thickness of the surface thermoplastic coating may range from about 5 to about 30 microns. The total coating thickness of the conductive yarns may be in the range of from about 10 to about 50 microns.

[0172] For illustration, example coating formulations were produced for testing. For example, the following composite coatings were produced for coating embodiments of #53 silver yarn.

[0173] A comparative example included #53 silver yarn coated with a TPU insulative coating, where the insulative coating was produced based on a 1stpass of 115201 with 2% wax, followed by a 2ndpass of a combination of U5201 / U615 (70:30 ratio) with 2% wax.

[0174] A first example (with insulated yarn identifier AC1485 T3 S2a) included insulated #53 silver yarn coated with a 1stpass coating of SEBS-g-MA including 10% carbon black material, followed by a 2ndpass coating of TPU dispersion (U5201 : U615 = 70:30 ratio + 2% wax).

[0175] A second example (with insulated yarn identifier AC 1485 T3 S2b) included insulated #53 silver yarn coated with a 1stpass coating of SEBS-g-MA containing 10% carbon black material, followed by a 2ndpass coating of TPU dispersion (U5201 :U615 = 50:50 ratio + 2% wax).

[0176] To illustrate, referring again to FIG. 17, the second example formulation was illustrated in the SEM images.

[0177] In some embodiments, a textile body may include a plurality of conductive and non- conductive fibers based on knitting, weaving, or embroidering operations, among other example textile construction methods.

[0178] In some embodiments, the textile body may comprise a first conductive yarn including a conductive fiber, a hydrophobic layer coating the conductive fiber to form a composite conductive fiber; and a thermoplastic layer coating the composite conductive fiber. The textile body may comprise a second conductive yarn electrically coupled to the first conductive yarn at one or more engagement points. For example, the one or more engagement points may be at the yarn interface 1040 illustrated in FIG. 10. The one or more engagement points may be coated by a combination of melted portions of the hydrophobic layer and the thermoplastic layer based on annealing operations. In some embodiments, the melted combination may be based on annealing operations including heating a region proximal to the one or more engagement points at a temperature within a range of 125 degrees Celsius to 140 degrees Celsius.

[0179] In some embodiments, the hydrophobic layer includes a mixture of polystyrene and carbon black material circumferentially surrounding the first conductive fiber. In some embodiments, the hydrophobic layer may include 10% carbon black material.

[0180] In some embodiments, the hydrophobic layer may include a mixture of polystyrene- block-poly(ethylene-ran-butylene-block-polystyrene-graft-maleic anhydride (SEBS-g-MA) and Vulcan-72 carbon black material circumferentially surrounding the first conductive fiber.

[0181] In some embodiments, the thermoplastic layer includes a mixture of two or more thermoplastic polyurethane (TPU) materials. In some embodiments, the thermoplastic layer may include a mixture of TPU-615, TPU-5201 , and a wax dispersion. In some embodiments, the thermoplastic layer may be a composition including TPU-5201 and TPU-615 according to a 70:30 TPU-5201 to TPU-615 ratio. In some embodiments, the thermoplastic layer includes a 2% wax dispersion.

[0182] In some embodiments, the conductive yarns may include at least one of metalized polymer yarns, hybrid conductive yarns, or conductive polymer yarns. In some embodiments, the conductive yarn may be a plurality of silver-plated nylon fibers. In some embodiments the secondconductive yarn may include one or more of the hydrophobic layer or thermoplastic layer. For example, the second conductive yarn may be a different type of conductive yarn having different electrical characteristics (e.g., resistive properties, etc.) as compared to the first conductive yarn. Thus, the combination of the first conductive yarn and the second conductive yarn may form a textile garment in accordance with some embodiments of the present disclosure.

[0183] As described in the present disclosure, embodiments of conductive yarns may be electrically coupled at a yarn interface based on embodiments of yarn coatings and configuration of knitted yarns being subject to annealing operations. To test and validate embodiments of coating formulations described in the present disclosure, electrical coupling or activation of swatch electrodes to provide electrical connection among carbon yarns and insulated silver trace yarns interlaced with textile bodies was performed based on thermal annealing operations in an oven. After colling to ambient temperatures, electrical properties of such electrode devices were measured. To validate electrical coupling between carbon yarns of a textile electrode and coated silver trace yarns of swatch textile bodies, resistance measurements were taken between a textile electrode and electrical pads before and after annealing operations for activating electrical coupling among carbon yarns and coated silver trace yarns. An illustration of the observed results involving the above-described comparison example and examples 1 and 2 are provided in the table below.Electrical Properties of Swatch Electrodes with Insulated TracesReference: ~ 3 kQ with 53 Silver

[0184] In recording the observed electrical properties of example swatch electrodes (see table above), resistance measurements were obtained for exampled by obtaining a resistance I resistance measurement between an electrode 610 (FIG. 7) and an electrical pad 630 (FIG. 7).In the above-described empirically-obtained test results, resistance measurements were taken with a multi-meter measurement instrument device.

[0185] As described in the present disclosure, it may be desirable to provide yarn coatings having properties to reduce occurrences of coating delamination from respective yarns based on textile laundering over time. To illustrate desirable properties of some embodiments described in the present disclosure, a set of laundering cycle operations were conducted to test example textile garment samples having coated #53 silver yarns for evaluating electrical stability of yarns after multiple laundering cycles.

[0186] Before laundering cycles, example textile garment samples having coated conductive yarns were subjected to embodiments of thermal annealing operations for activating electrical coupling for example of adjoining carbon yarns and coated conductive yarns based on controlled annealing temperatures.

[0187] FIG. 18 illustrates a chart 1800 illustrating resistance measurement values between a textile electrode and a test electrical pad, where the example textile garment included coated conductive yarns based on the “comparison example” properties described above. The textile garment was subjected to annealing temperatures of approximately 160 degrees Celsius for activating electrical coupling between carbon yarns (of the textile electrode) and coated conductive yarns (of transmission line type traces). The chart 1800 illustrates that electrical resistance of the coated conductive yarns increased with increasing number of laundering cycles.

[0188] For comparison, a set of laundering cycle operations were conducted on text example textile garment samples having coated #53 silver yarns based on “example 2” properties described above. Example 2 included insulated #53 silver yarn obtained based on a first pass coating of SEBS-g-MA containing 10% carbon black material, followed by a second pass coating of TPU dispersion (115201 :11615 with a ratio of 50:50, including 2% wax dispersion).

[0189] As illustrated in FIG. 19, annealing operation temperatures of approximately 125 degrees Celsius and of approximately 140 degrees Celsius for activating electrical coupling between carbon yarns (of the textile electrode) and coated conductive yarns (of transmission line type traces). The chart 1900 illustrates that empirically observed electrical resistance of the coated conductive yarns increased at a markedly reduced rate over increasing number of laundering cycles.

[0190] To empirically test coated conductive yarns with prototype textile garments including textile electrodes for detecting data signals for generating electrocardiogram (ECG) data associated with a user, ECG measurement data was obtained using prototype textile garments. The prototype textile garments included coated #53 silver yarns having “example 1” properties described above. Example 1 included insulated #53 silver yarn prepared based on a first pass coating of SEBS-g-MA containing 10% carbon black material, followed by a second pass coating of a TPU dispersion (115201 :11615 in 70:30 ratio, and 2% wax dispersion).

[0191] FIG. 20 illustrates charts 2000 of ECG measurement data of a user obtained when lotion was applied to the textile electrode of the prototype textile garment.

[0192] FIG. 21 illustrates charts 2100 of ECG measurement data of a user obtained when lotion was not applied to the textile electrode of the prototype textile garment.

[0193] Based on the charts 2000, 2100 of FIG. 20 and FIG. 21 , respectively, integration of embodiments of coated conductive yarns in prototype textile garments provided good ECG measurement data, thereby validating features of (and methods of producing) embodiments of coated conductive yarns described in the present disclosure.

[0194] Embodiments of the present disclosure describe conductive yarns with composite coatings to provide electrical transmission lines for textile computing applications. In some described embodiments, hydrophobic composite coatings having carbon black material may provide moisture barriers whilst thermoplastic polyurethane combination coatings may provide desirable abrasion resistance. In some scenarios, the addition of conductive carbon black material may provide for lower thermal annealing temperatures for electrically coupling coated conductive yarns with adjacent or adjoining conductive yarns. The observed lower thermal annealing temperatures may be compared to embodiments of coatings that may not include carbon black material.

[0195] As illustrated in empirical test results shown in experiments described in the present disclosure, some embodiments of the present disclosure provide for increased electrical coupling consistency over numerous laundering cycles, as compared to other example coated conductive yarns that may exhibit increasing electrical resistivity in conductive traces with increasing laundering cycles. In addition, empirical test results described in the present disclosure illustrate annealing operations having lower annealing temperatures were achieved, which may contribute to reduced coating delamination from conductive yarns.

[0196] Reference is made to FIG. 22, which illustrates a flowchart of a method 2200 of producing a textile body, in accordance with embodiments of the present disclosure.

[0197] The method 2200 may be conducted by one or more textile manufacturing apparatus in combination with an integral or downstream annealing apparatus for electrically coupling insulated conductive yarns interlaced in textile bodies.

[0198] At operation 2202, the apparatus may construct the textile body including a first conductive yarn and a second conductive yarn interlaced with the first conductive yarn at one or more engagement points. In some embodiments, the textile body may be constructed based on flat knitting at least the first conductive yarn and the second conductive yarn.

[0199] In some embodiments, the fist conductive yarn may include a conductive fiber, a hydrophobic layer coating the conductive fiber to form a composite conductive fiber, and a thermoplastic layer coating the composite conductive fiber.

[0200] In some embodiments, constructing the textile body may include coating the first conductive yarn with SEBS-g-MA containing 10% carbon black to form a composite conductive fiber; and coating the first conductive yarn with a thermoplastic polyurethane dispersion including 115201 and 11615 according to a 70 to 30 ratio of 115201 to U615. In some embodiments, coating the first conductive fiber with the hydrophobic layer precedes coating operations including coating the composite conductive fiber with the thermoplastic layer.

[0201] In some embodiments, the apparatus may be configured to formulate the hydrophobic layer by mixing polystyrene-block-poly(ethylene-ran-butylene-block-polystyrene-graft-maleic anhydride (SEBS-g-MA) and Vulcan-72 carbon black material in toluene; and ball milling the hydrophobic layer with stainless shotts for approximately 48 hours. The hydrophobic layer may then be used to coat the first conductive fiber to form the composite conductive fiber.

[0202] In some embodiments, the apparatus may be configured to formulate the thermoplastic layer by mixing Albedingk 115201 and 11615 according to a 70 to 30 ratio of 115201 to U615 and wax dispersion; and air stripping at 50 degrees Celsius to provide a viscosity for coating conductive yarn. The thermoplastic layer may then be used to coat the composite conductive fiber.

[0203] At operation 2204, the apparatus may conduct annealing operations to direct heat proximal to the one or more engagement points to electrically couple the first conductive yarn andthe second conductive yarn by melting the hydrophobic layer and the thermoplastic layer at the one or more engagement points. In some situations, by melting the hydrophobic layer and the thermoplastic layer, the first conductive fiber and the second conductive fiber may be physically adjoined or touch, thereby become electrically coupled.

[0204] In some embodiments, annealing the textile body may include directing heat at least to the one or more engagement points to a temperature within a range of 125 degrees Celsius to 140 degrees Celsius for a threshold time duration. In some embodiments, the threshold time duration may be 10 minutes. Other threshold time durations may be contemplated based on the rheological characteristics of the coating compositions.

[0205] In some embodiments, the annealing operations may include modulating the heat directed to the one or more engagement points over the threshold time duration.

[0206] At operation 2206, the apparatus may conduct cooling operations for cooling the textile body to coat the one or more engagement points with a combination of a portion of the hydrophobic and a portion of the thermoplastic layers. In some situations, when the textile body is cooled, melted portions of the hydrophobic and thermoplastic layers may settle at the physically touching or adjoining engagement points of the first conductive fiber and the second conductive fiber. Accordingly, the cooled melted portions of the hydrophobic and thermoplastic layers may form an insulative composite coating to provide a moisture and abrasion resistant barrier.

[0207] In some embodiments, the apparatus may conduct tensioning operations for tensioning the first conductive yarn relative to the second conductive yarn to promote physical contact at the one or more engagement points.

[0208] The term “connected” or "coupled to" may include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements).

[0209] Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the scope. Moreover, the scope of the present disclosure is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification.

[0210] As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

[0211] The description provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

[0212] As can be understood, the examples described above and illustrated are intended to be exemplary only.

[0213] Applicant notes that the described embodiments and examples are illustrative and non-limiting. Practical implementation of the features may incorporate a combination of some or all of the aspects, and features described herein should not be taken as indications of future or existing product plans. Applicant partakes in both foundational and applied research, and in some cases, the features described are developed on an exploratory basis.

Claims

WHAT IS CLAIMED IS:

1. A textile body comprising: a first conductive yarn including: a conductive fiber; and at least one coating layer surrounding the conductive fiber to form a composite conductive fiber; the at least one coating layer being a thermoplastic layer; and a second conductive yarn electrically coupled to the first conductive yarn at one or more engagement points, the one or more engagement points being encapsulated by one or more portions of the at least one coating layer.

2. The textile body of claim 1, wherein the at least one coating layer is a hydrophobic layer comprised of a hydrophobic polymer.

3. The textile body of claim 1 , wherein the first conductive yarn further includes a hydrophobic layer comprised of a hydrophobic polymer.

4. The textile body of claim 3, wherein the hydrophobic layer comprises a hydrophobic polymer selected from a group consisting of styrene copolymers, vinyl chloride and vinyl acetate copolymers, and polyvinylidene fluoride copolymers.

5. The textile body of claim 2, wherein the hydrophobic layer includes a mixture of a hydrophobic polymer and a carbon black material circumferentially surrounding the first conductive fiber.

6. The textile body of claim 5, wherein the hydrophobic layer is a composition including from about 1 to about 20 weight percent of the carbon black material.

7. The textile body of claim 5, wherein the hydrophobic layer circumferentially surrounding the first conductive fiber includes a mixture of a conductive carbon material and a hydrophobic polymer selected from the group of a polystyrene-block-poly(ethylene-ran-butylene-block- polystyrene-graft-maleic anhydride (SEBS-g-MA), a terpolymer comprised of vinyl chloride, vinyl acetate and maleic acid (VMCH), and a poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF- HFP).

8. The textile body of claim 1 , wherein the thermoplastic layer comprises a thermoplastic polyurethane (TPU) or poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP).

9. The textile body of claim 1 , wherein the thermoplastic layer includes a mixture of a polycarbonate-based thermoplastic polyurethane and a polyester-based thermoplastic polyurethane.

10. The textile body of claim 9, wherein the ratio of polyester-based thermoplastic polyurethane and polycarbonate-based thermoplastic polyurethane is from about 20:80 to about 80:20.

11. The textile body of claim 9, wherein the thermoplastic layer is a composition including a wax additive at a loading ranging from about 1 to about 5 weight percents.

12. The textile body of claim 1 , wherein the one or more portions of the at least one coating layer are formed based on an annealing operation including heating a region proximal to the one or more engagement points at a temperature within a range of about 100 degrees Celsius to about 160 degrees Celsius.

13. The textile body of claim 1 , wherein the one or more engagement points are based on at least one of knitted, weaving, or embroidered structures.

14. The textile body of claim 1 , wherein the first conductive yarn includes at least one of metalized polymer yarns, hybrid conductive yarns, or conductive polymer yarns.

15. A method of producing a textile body comprising: constructing the textile body including a first conductive yarn and a second conductive yarn interlaced with the first conductive yarn at one or more engagement points, wherein the first conductive yarn includes a conductive fiber and at least one coating layer surrounding the conductive fiber to form a composite conductive fiber, the at least one coating layer being a thermoplastic layer; conducting one or more annealing operations to direct heat proximal to the one or more engagement points to electrically couple the first conductive yarn and the second conductive yarn by increasing the temperature of the thermoplastic layer to near its melting point at the one or more engagement points; and cooling the textile body to encapsulate the one or more engagement points with the at least one coating layer.

16. The method of claim 15, wherein the at least one coating layer is a hydrophobic layer comprised of a hydrophobic polymer.

17. The method of claim 16, comprising formulating the composite conductive fiber using a hydrophobic polymer selected from a group consisting of styrene copolymers, vinyl chloride and vinyl acetate copolymers, and polyvinylidene fluoride copolymers.

18. The method of claim 16, comprising formulating the composite conductive fiber using a mixture of a hydrophobic polymer and a carbon black material circumferentially surrounding the first conductive fiber.

19. The method of claim 18, comprising formulating the composite conductive fiber using about 1 to 20 percent carbon black material.

20. The method of claim 15, wherein the one or more annealing operations includes directing heat to at least of the engagement points to a temperature within a range of about 100 degrees Celsius to 160 degrees Celsius for a threshold time duration.

21. The method of claim 20, wherein annealing the textile body includes modulating the heat directed to the one or more engagement points over the threshold time duration.

22. The method of claim 15, comprising tensioning the first conductive yarn relative to the second conductive yarn to promote contact at the one more engagement points.

23. The method of claim 15, wherein constructing the textile body including the first conducting yarn and the second conductive yarn comprises flat knitting at least the first conductive yarn and the second conductive yarn.

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