Integrally formed multi-layer flexible fabric circuit

Abstract

The present invention relates to the technical field of flexible circuits. Disclosed is an integrally formed multi-layer flexible fabric circuit. On the basis of functional layout classification, the integrally formed multi-layer flexible fabric circuit comprises a main circuit I, a branch circuit I, a main circuit II, and a branch circuit II. The main circuit I is connected to the branch circuit II, the main circuit II is connected to the branch circuit II, the main circuit I is not connected to the main circuit II, and the branch circuit I is not connected to the branch circuit II. The main circuit I and the main circuit II define a U-shaped area, and both the branch circuit I and the branch circuit II are located in the area. On the basis of structural composition classification, the integrally formed multi-layer flexible fabric circuit comprises an insulating warp-knitted fabric, and a single conductive yarn a, a single conductive yarn b, and a plurality of conductive yarns X that are simultaneously located in the insulating warp-knitted fabric. The conductive yarn a and the conductive yarn b respectively are weft yarns inlaid into the insulating warp-knitted fabric from the left and right sides. The present invention has the advantages of light weight, softness, and breathability, has good ductility, is integrally formed during weaving, and maintains the integrity of the structure and the continuity of the yarns.

Description

A one-piece molded multilayer flexible fabric circuit Technical Field

[0001] This invention belongs to the field of flexible circuit technology and relates to an integrally molded multilayer flexible fabric circuit. Background Technology

[0002] The rapid development of smart textile technologies has led to widespread attention being paid to flexible circuits based on fabrics due to their superior flexibility and breathability, especially in fields such as motion recognition and health monitoring. Traditional smart textiles typically combine rigid materials or semiconductors with fabrics using thick wires. However, their bulkiness, susceptibility to wear, and inability to deform with the fabric fail to meet the diverse needs of daily life. Therefore, a lightweight, soft, and skin-friendly flexible circuit has emerged. Flexible circuits are mainly composed of conductive materials such as metal nanoparticles, metal oxides, and conductive polymers, doped with flexible substrates such as paper, thin films, and silicone. They typically possess high elasticity and wear resistance, but poor breathability. In contrast, flexible circuits based on fabrics offer superior flexibility and breathability, allowing for bending, twisting, and stretching at any angle, thus meeting the requirements of daily life.

[0003] Currently, common methods for fabricating flexible circuits include screen printing, inkjet printing, and the introduction of conductive yarns.

[0004] Screen printing is mainly used to prepare fabric sensors. For example, patent application US20230181110A1 discloses a fabric circuit system for infant health monitoring, which integrates flexible printed circuits into an infant kit and connects temperature sensors through circuit layout design to transmit the collected temperature signals. Patent application US20230358570A1 discloses a strain sensing system for vehicles, which uses conductive ink to form sensing circuits or shielding circuits on flexible insulating substrates such as fabrics through screen printing. The substrate is an elastic memory film or fabric, which can reduce the damage to the printed circuits on the fabric surface during repeated tension and relaxation. The literature (Circuit Design and Performance of Electrothermal Composite Fabrics [J]. Printing and Dyeing, 2020, 46(03):1-4+14.) proposes a method that uses silver paste as a conductive and heating material, prints series or parallel circuits on a thermoplastic polyurethane (TPU) film using screen printing, then uses a second TPU film to bond and encapsulate it, and finally uses two pieces of polyester fabric to composite the upper and lower surfaces to prepare a flexible electrothermal composite fabric. The circuit is divided into two types: series and parallel, serving as both a conductive circuit and a heating material. Because it employs a composite of two thin films and two fabric layers, the final fabric has a high basis weight and is not breathable. A similar prior art technique is patent application CN202310911132.9, which discloses a large-size double / multilayer flexible fabric substrate thin film circuit and its fabrication method. This method involves screen printing two separate circuit layers onto two thermoplastic films using a conductive paste. Flexible fabric circuits must meet certain mechanical performance requirements; most printing is performed under low mechanical stress, and the resistance of the printed flexible circuit changes during stretching. For complex circuits, changes in wire resistance will affect the normal operation of the entire connecting wire.

[0005] Inkjet printing is a rapid additive manufacturing method that sprays ink droplets onto a substrate to form conductive patterns. This method is characterized by non-contact operation, high resolution, high precision, and rapid digital prototyping. For example, patent ZL202222414823.1 discloses a flexible, tensile-resistant printed circuit fabric. The circuits are arranged in a wave-like pattern on a conductive layer, allowing the fabric to stretch along with it. Through the cooperation of printed circuits made of conductive silver paste and sensors, it can collect human signals upon contact with the human body. However, the dispersed silver particles during inkjet printing easily clog the nozzles, requiring optimization of the ink formulation and printing process to improve ink printing capacity. Furthermore, the printed pattern must be sintered at high temperatures to achieve conductivity, which can cause irreversible damage to the fabric substrate. Secondly, the thickness of the cured conductive material deposited by inkjet printing is typically less than 1 μm, making it difficult to print a continuous conductive layer on rough fabric surfaces. A similar prior art patent, CN202310283345.1, shows that when printing circuits onto fabric using this method, the fabric often exhibits poor ductility and stability as it bends and stretches.

[0006] The conductive yarn introduction method involves using traditional weaving techniques such as embroidery, weaving, and knitting to introduce conductive yarns into the fabric structure to form conductive connecting wires. This type of conductive fabric is lightweight and breathable, possessing both the comfort of ordinary fabrics and excellent conductivity. Embroidery, which introduces wires onto the fabric surface, makes the fabric stiffer, reducing its overall extensibility and making it unsuitable for circuit design in close-fitting fabrics. For example, patent application CN202010072986.9 uses a weaving method to weave conductive metal wires and surface-insulating conductive tape together to form a fabric circuit. Patent ZL201720616339.3 and patent application CN201810417358.2 respectively use weaving and knitting methods to weave conductive and non-conductive threads together into a plain weave fabric. Patent ZL202122012574.9 inserts conductive yarns into the warp-knitted base as weft inserts, achieving a regular or irregular zigzag, wavy, or trapezoidal distribution of the conductive yarns. Patent application CN201010120005.X designs a double-layer conductive woven fabric. The first and second layers are woven with conductive and non-conductive threads, respectively, with the non-conductive threads weaving the first and second layers together. The aforementioned conductive yarn-introduced conductive fabric only introduces the conductive yarn into the fabric substrate, without introducing electrodes into the fabric to form a complete fabric circuit. Patent ZL202020922231.9 invented a fabric heating element, where a single-layer fabric is divided into an electrode section and a heating section. However, some of the electrode yarns introduced into the fabric still require external wires to connect to the power supply, failing to truly achieve a complete, integrated fabric circuit. Patent ZL202110495938.5 discloses a multi-layer woven composite heating fabric, whose internal fabric circuit is formed by two sets of conductive warp and weft yarns interwoven separately. Furthermore, the warp yarns in the two sets of conductive yarns are staggered with insulating yarns to avoid contact with the conductive weft yarns of the other set. The two sets of conductive yarns in this fabric circuit can be directly connected to the electrodes without the need for additional external wires, but the multi-layered interweaving makes the fabric stiff and has poor extensibility.

[0007] Therefore, researching a truly complete flexible fabric circuit is of great significance for enhancing its flexibility and comfort in various application scenarios. Summary of the Invention

[0008] The purpose of this invention is to solve the problems existing in the prior art and provide an integrally molded multilayer flexible fabric circuit.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0010] An integrally formed multi-layer flexible fabric circuit, classified by functional layout, includes a main circuit I, a branch circuit I, a main circuit II, and a branch circuit II. The main circuit I is connected to the branch circuit I, the main circuit II is connected to the branch circuit II, the main circuit I is not connected to the main circuit II, and the branch circuit I is not connected to the branch circuit II;

[0011] The main circuit I and the main circuit II enclose a "匚"-shaped area, and both the branch circuit I and the branch circuit II are located within this area;

[0012] The resistance ratio of the main circuit I to the branch circuit I is not less than 6, and the resistance ratio of the main circuit II to the branch circuit II is not less than 6. This can ensure that current can be transmitted to the entire main circuit and branch circuit, and prevent the current from forming a closed loop in some length segments of the main circuit and branch circuit, making it impossible to transmit to the entire main circuit and branch circuit;

[0013] Classified by composition structure, it includes an insulating warp knitted fabric and a single conductive yarn a, a single conductive yarn b, and multiple (i.e., two or more) conductive yarns X located inside it at the same time;

[0014] The conductive yarn a is a weft yarn inserted into the insulating warp knitted fabric from the left side, and the conductive yarn b is a weft yarn inserted into the insulating warp knitted fabric from the right side;

[0015] The main circuit I is composed of a part of the conductive yarn a and a part of the conductive yarn X in contact with it, the branch circuit I is composed of another part of the conductive yarn a, the main circuit II is composed of a part of the conductive yarn b and another part of the conductive yarn X in contact with it, and the branch circuit II is composed of another part of the conductive yarn b.

[0016] As a preferred technical solution:

[0017] [[ID=​​​​​​​​The main circuit I consists of the left part of conductive yarn a and the conductive yarn c in contact with it; the branch circuit I consists of the right part of conductive yarn a; the main circuit II consists of the left rear part of conductive yarn b, the conductive yarn d in contact with the left rear part, the right part of conductive yarn b, and the conductive yarn e in contact with the right part; and the branch circuit II consists of the left front part of conductive yarn b.

[0021] As described above, in a one-piece molded multilayer flexible fabric circuit, multiple conductive yarns Y are woven into the loops and extensions of the insulating warp-knitted fabric in a weft-insertion manner or in loops; multiple conductive yarns e are woven into the loops and extensions of the insulating warp-knitted fabric in a weft-insertion manner or in loops; when conductive yarns Y or e are woven into the loops and extensions of the insulating warp-knitted fabric in a weft-insertion manner, the tensile performance of the entire multilayer flexible fabric circuit is excellent due to the good stretchability of conductive yarns Y or e along the warp direction; when conductive yarns Y or e are woven into the loops and extensions of the insulating warp-knitted fabric in loops, the resistance of the main circuit I and the main circuit II is relatively small.

[0022] As described above, in a one-piece molded multi-layer flexible fabric circuit, all looping methods are selected from one of chain braiding, plain warp, pile warp, and twill warp.

[0023] As described above, a one-piece molded multilayer flexible fabric circuit, classified by its composition structure, also includes electrodes located on the surface of the insulating warp-knitted fabric, with one end of multiple conductive yarns c and multiple conductive yarns d protruding from the insulating warp-knitted fabric and connected to the positive and negative electrodes, respectively.

[0024] As described above, a one-piece molded multilayer flexible fabric circuit, classified by its composition structure, also includes conductive yarn f located inside the insulating warp-knitted fabric, which simultaneously contacts branch circuit I and branch circuit II.

[0025] As described above, in a one-piece molded multilayer flexible fabric circuit, conductive yarn f is woven into the loops and extension threads of the insulating warp-knitted fabric in a manner that involves weaving in warp, weft, or loops.

[0026] As described above, in a one-piece molded multilayer flexible fabric circuit, the linear resistance of conductive yarn f is 100-5000Ω / cm, and the linear resistance of conductive yarn a and conductive yarn b is 0.01-1Ω / cm, which allows the current to be applied to conductive yarn f as much as possible.

[0027] The present invention also provides an integrally formed multilayer flexible fabric circuit, comprising an insulating weft-knitted double-sided fabric and a single conductive yarn g and a single conductive yarn h located inside it.

[0028] Conductive yarn g and conductive yarn h do not come into contact;

[0029] The conductive yarn g is divided into two parts, left and right. The left part is woven into the front and back loops of the insulating weft-knitted double-sided fabric by adding yarn to form loops. The left part constitutes the main circuit III, and the right part constitutes the branch circuit III.

[0030] The conductive yarn h is divided into two parts, left and right. The right part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The right part constitutes the main circuit IV, and the left part constitutes the branch circuit IV.

[0031] The resistance ratio of the main circuit III to the branch circuit III is not less than 6, and the resistance ratio of the main circuit IV to the branch circuit IV is not less than 6. This ensures that the current can be transmitted to the entire main circuit and branch circuit, and avoids the current from forming a closed loop in a certain length of the main circuit and branch circuit, which would prevent the current from being transmitted to the entire main circuit and branch circuit.

[0032] As a preferred technical solution:

[0033] In the integrally molded multilayer flexible fabric circuit described above, the right part of the conductive yarn g is a float; the left part of the conductive yarn h is a float.

[0034] The integrally formed multilayer flexible fabric circuit described above further includes electrodes located on the surface of the insulating weft-knitted double-sided fabric; one end of the conductive yarn g and the conductive yarn h protrudes from the same side of the insulating weft-knitted double-sided fabric and is connected to the positive and negative electrodes, respectively.

[0035] The integrally formed multilayer flexible fabric circuit described above also includes conductive yarn i located inside the insulating weft-knitted double-sided fabric, and conductive yarn i is in contact with both branch circuit III and branch circuit IV.

[0036] As described above, in a one-piece molded multilayer flexible fabric circuit, conductive yarn i is woven into the front and back coils of the insulating weft-knitted double-sided fabric in a looping manner.

[0037] As described above, in a one-piece molded multilayer flexible fabric circuit, the linear resistance of conductive yarn i is 100-5000Ω / cm, and the linear resistance of conductive yarn g and conductive yarn h is 0.01-1Ω / cm, which allows the current to be applied to conductive yarn i as much as possible. Beneficial effects

[0038] The one-piece molded multilayer flexible fabric circuit of the present invention is integrally molded during weaving, requiring no cutting or only one cutting, thus maintaining the integrity of the structure and the continuity of the yarn.

[0039] The integrally molded multilayer flexible fabric circuit body of the present invention is an insulating warp-knitted fabric or an insulating weft-knitted double-sided fabric with good extensibility, and the warp elongation and weft elongation can reach 30% and 15%, respectively. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 and FIG. 2 are schematic views of the integrally formed multi - layer flexible fabric circuit according to Embodiment 1 of the present invention;

[0041] FIG. 3 is an exploded schematic view of the integrally formed multi - layer flexible fabric circuit according to Embodiment 1 of the present invention;

[0042] FIG. 4 is an exploded schematic view of the integrally formed multi - layer flexible fabric circuit according to Embodiment 2 of the present invention;

[0043] FIG. 5 is an exploded schematic view of the integrally formed multi - layer flexible fabric circuit according to Embodiment 3 of the present invention;

[0044] Among them, 1 is the integrally formed multi - layer flexible fabric circuit, 2 - 1 is the process front side of the insulating warp knitted fabric, 2 - 2 is the process reverse side of the insulating warp knitted fabric, 3 is the conductive yarn X, 4 is the conductive yarn f, 5 is the conductive yarn b, 6 is the main circuit I, 7 is the branch circuit I, 8 is the main circuit II, and 9 is the branch circuit II. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0045] The present invention will be further described below in conjunction with the specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and not to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by the appended claims of this application. Embodiment 1

[0046] An integrally formed multi - layer flexible fabric circuit, as shown in FIG. 2, includes a main circuit I 6, a branch circuit I 7, a main circuit II 8, and a branch circuit II 9 according to the functional layout classification. The main circuit I 6 is connected to the branch circuit I 7, the main circuit II 8 is connected to the branch circuit II 9, the main circuit I 6 is not connected to the main circuit II 8, and the branch circuit I 7 is not connected to the branch circuit II 9;

[0047] The main circuit I 6 and the main circuit II 8 enclose a "匚" - shaped area, and both the branch circuit I 7 and the branch circuit II 9 are located within this area;

[0048] The resistance ratio of the main circuit I 6 to the branch circuit I 7 is 6, and the resistance ratio of the main circuit II 8 to the branch circuit II 9 is 6;

[0049] As shown in Figure 1, the integrally formed multilayer flexible fabric circuit 1 is classified according to its composition structure as follows: it consists of an insulating warp-knitted fabric (composed of insulating yarn, which is polyacrylonitrile pre-oxidized yarn with a specification of 40s, divided into the process front 2-1 and the process back 2-2 of the insulating warp-knitted fabric), electrodes located on the surface of the insulating warp-knitted fabric, and a single conductive yarn a (the linear resistance of conductive yarn a is 0.04Ω / cm, and conductive yarn a is made of 9 copper wires with a diameter of 0.03mm twisted together), a single conductive yarn b 5 (the linear resistance of conductive yarn b is 0.04Ω / cm, and conductive yarn b is made of 9 copper wires with a diameter of 0.03mm twisted together), conductive yarn X 3, and conductive yarn f 4 (conductive yarn f is polyester fiber coated with carbon nanotube conductive paste, with a specification of 70D and a linear resistance of 2000Ω / cm).

[0050] Conductive yarn a is a weft yarn inserted into the insulating warp-knitted fabric from the left side, consisting of two parts, left and right;

[0051] Conductive yarn b 5 is a weft yarn inserted into the insulating warp-knitted fabric from the right side, consisting of two parts, left and right. The left part is divided into a front left part and a rear left part arranged along the warp direction.

[0052] Conductive yarn a is located on the front side of the left rear part of conductive yarn b 5;

[0053] The conductive yarn X 3 is composed of multiple conductive yarns c, multiple conductive yarns d, and multiple (30) conductive yarns e (the linear resistance of conductive yarn e is 0.04Ω / cm, and conductive yarn e is made of 9 copper wires with a diameter of 0.03mm twisted together).

[0054] Multiple conductive yarns c and multiple conductive yarns d correspond to the front and back sections formed by cutting multiple (30) conductive yarns Y (the linear resistance of conductive yarn Y is 0.04Ω / cm, and conductive yarn Y is made of 9 copper wires with a diameter of 0.03mm twisted together). One end of multiple conductive yarns c and multiple conductive yarns d are exposed from the reverse side 2-2 of the insulating warp-knitted fabric and are connected to the positive and negative electrodes respectively.

[0055] Main circuit I 6 is composed of the left part of conductive yarn a and conductive yarn c in contact with it; branch circuit I 7 is composed of the right part of conductive yarn a; main circuit II 8 is composed of the left rear part of conductive yarn b 5, conductive yarn d in contact with the left rear part, the right part of conductive yarn b 5, and conductive yarn e in contact with the right part; branch circuit II 9 is composed of the left front part of conductive yarn b 5.

[0056] Conductive yarn f4 is in contact with both branch circuit I 7 and branch circuit II 9 simultaneously;

[0057] As shown in Figure 3, multiple conductive yarns Y are woven between the loop stems and the延展线 (it seems there is a missing word here, perhaps "extension yarns") of the insulating warp knitted fabric in the form of warp insertion; multiple conductive yarns e are woven between the loop stems and the extension yarns of the insulating warp knitted fabric in the form of warp insertion; the conductive yarn f 4 is woven between the loop stems and the extension yarns of the insulating warp knitted fabric in the form of weft insertion.

[0058] The preparation method of the integrally formed multi-layer flexible fabric circuit as described above is as follows: A single needle bed warp knitting machine with two large lateral movement pattern combs and three ground combs is used for knitting. The arrangement order of the combs from the front of the machine to the back is: GB1 (ground comb), GB2 (ground comb), GB3 (ground comb), PB1 (large lateral movement pattern comb), PB2 (large lateral movement pattern comb). During the knitting process, GB1 forms a plain stitch, GB2 does warp insertion, GB3 does 1 needle of weft insertion, and PB1 and PB2 do weft insertion movement according to the trajectory shown in Figure 3. Then, the knitted fabric is taken off the machine, the conductive yarn Y is cut according to Figure 3, and the electrodes are connected to obtain the integrally formed multi-layer flexible fabric circuit 1. Among them, GB1 is fully threaded with insulating yarn, GB2 is fully threaded with 30 conductive yarns X on both the left and right sides, GB3 is fully threaded with conductive yarn f, PB1 is threaded with 1 conductive yarn a, and PB2 is threaded with 1 conductive yarn b. Example 2

[0059] An integrally formed multi-layer flexible fabric circuit, as shown in Figure 4, includes a main circuit I, a branch circuit I, a main circuit II, and a branch circuit II according to the functional layout classification. The main circuit I is connected to the branch circuit I, the main circuit II is connected to the branch circuit II, the main circuit I is not connected to the main circuit II, and the branch circuit I is not connected to the branch circuit II.

[0060] The main circuit I and the main circuit II enclose a "匚" - shaped area, and both the branch circuit I and the branch circuit II are located within this area.

[0061] The resistance ratio of the main circuit I to the branch circuit I is 10, and the resistance ratio of the main circuit II to the branch circuit II is 10.

[0062] According to the composition structure classification, it consists of an insulating warp knitted fabric (constituted by insulating yarn, the insulating yarn is a flame-retardant nylon filament with a specification of 100D / 48F), electrodes located on the surface of the insulating warp knitted fabric, and a single conductive yarn a (the linear resistance of the conductive yarn a is 0.025Ω / cm, and the conductive yarn a is twisted from 12 copper wires with a diameter of 0.03mm), a single conductive yarn b (the linear resistance of the conductive yarn b is 0.025Ω / cm, and the conductive yarn b is twisted from 12 copper wires with a diameter of 0.03mm), conductive yarn X, and conductive yarn f (the conductive yarn f is pre-oxidized yarn low-temperature carbonized, and the linear resistance is 3000Ω / cm) located inside the insulating warp knitted fabric at the same time.

[0063] Conductive yarn a is a weft yarn inserted into the insulating warp-knitted fabric from the left side, consisting of two parts, left and right;

[0064] Conductive yarn b is a weft yarn inserted into the insulating warp-knitted fabric from the right side, consisting of two parts, left and right. The left part is divided into a front left part and a rear left part arranged along the warp direction.

[0065] Conductive yarn a is located on the front side of the left rear part of conductive yarn b;

[0066] The conductive yarn X is composed of multiple conductive yarns c, multiple conductive yarns d, and multiple (30) conductive yarns e (conductive yarn e is copper wire with a diameter of 0.03mm, made of 12 twisted strands, and has a line resistance of 0.025Ω / cm);

[0067] Multiple conductive yarns c and multiple conductive yarns d correspond to the front and back sections formed by cutting multiple (30) conductive yarns Y (conductive yarn Y is copper wire with a diameter of 0.03mm, made of 12 twisted strands, with a line resistance of 0.025Ω / cm). One end of multiple conductive yarns c and multiple conductive yarns d are exposed from the reverse side of the insulating warp-knitted fabric and connected to the positive and negative electrodes respectively.

[0068] Main circuit I consists of the left part of conductive yarn a and conductive yarn c in contact with it; branch circuit I consists of the right part of conductive yarn a; main circuit II consists of the left rear part of conductive yarn b, conductive yarn d in contact with the left rear part, the right part of conductive yarn b, and conductive yarn e in contact with the right part; branch circuit II consists of the left front part of conductive yarn b.

[0069] The conductive yarn f is in contact with both branch circuit I and branch circuit II simultaneously;

[0070] Multiple conductive yarns Y are woven into the loops and extensions of the insulating warp-knitted fabric in a weft-insertion manner; multiple conductive yarns e are woven into the loops and extensions of the insulating warp-knitted fabric in a weft-insertion manner; conductive yarn f is woven into the loops and extensions of the insulating warp-knitted fabric in a warp-insertion manner.

[0071] The preparation method of the integrally formed multi-layer flexible fabric circuit described above is as follows: A single needle bed warp knitting machine with two large cross-laying pattern combs and three ground combs is used for knitting. The arrangement order of the combs from the front of the machine to the back is: GB1 (ground comb), GB2 (ground comb), GB3 (ground comb), PB1 (large cross-laying pattern comb), PB2 (large cross-laying pattern comb). During the knitting process, GB1 forms a plain stitch, GB2 serves as a backing warp, GB3 serves as a 1-stitch backing weft, and PB1 and PB2 perform a backing weft movement according to the trajectory shown in Figure 3. Then, the knitted fabric is taken off the machine, the conductive yarn Y is cut according to Figure 3, and the electrodes are connected to obtain the integrally formed multi-layer flexible fabric circuit. Among them, GB1 is fully threaded with insulating yarn, GB2 is fully threaded with 30 conductive yarns X on each of the left and right sides, GB3 is fully threaded with conductive yarn f, PB1 is threaded with 1 conductive yarn a, and PB2 is threaded with 1 conductive yarn b. Example 3

[0072] An integrally formed multi-layer flexible fabric circuit, as shown in Figure 5, includes a main circuit I, a branch circuit I, a main circuit II, and a branch circuit II according to the functional layout classification. The main circuit I is connected to the branch circuit I, the main circuit II is connected to the branch circuit II, the main circuit I is not connected to the main circuit II, and the branch circuit I is not connected to the branch circuit II.

[0073] The main circuit I and the main circuit II enclose a "匚"-shaped area, and both the branch circuit I and the branch circuit II are located within this area.

[0074] The resistance ratio of the main circuit I to the branch circuit I is 20, and the resistance ratio of the main circuit II to the branch circuit II is 20.

[0075] According to the composition structure classification, it consists of an insulating warp knitted fabric (constituted by insulating yarn, the insulating yarn is wool yarn, with a specification of 60 Nm), electrodes located on the surface of the insulating warp knitted fabric, and a single conductive yarn a (the wire resistance of the conductive yarn a is 0.015 Ω / cm, and the conductive yarn a is twisted from 7 copper wires with a diameter of 0.05 mm), a single conductive yarn b (the wire resistance of the conductive yarn b is 0.015 Ω / cm, and the conductive yarn b is twisted from 12 copper wires with a diameter of 0.05 mm), conductive yarn X, and conductive yarn f (the conductive yarn f is low-temperature carbonized pre-oxidized fiber yarn, with a wire resistance of 5000 Ω / cm) located inside the insulating warp knitted fabric at the same time.

[0076] The conductive yarn a is a weft yarn inserted into the insulating warp knitted fabric from the left, and it consists of left and right parts.

[0077] The conductive yarn b is a weft yarn inserted into the insulating warp knitted fabric from the right, and it consists of left and right parts. The left part is divided into a left front part and a left rear part arranged along the warp direction. <​

[0079] The conductive yarn X is composed of multiple conductive yarns c, multiple conductive yarns d, and multiple (30) conductive yarns e (conductive yarn e is copper wire with a diameter of 0.05mm, made of 7 twisted strands, with a line resistance of 0.015Ω / cm);

[0080] Multiple conductive yarns c and multiple conductive yarns d correspond to the front and back sections formed by cutting multiple (30) conductive yarns Y (conductive yarn Y is copper wire with a diameter of 0.05mm, made of 7 twisted strands, with a line resistance of 0.015Ω / cm). One end of multiple conductive yarns c and multiple conductive yarns d are exposed from the reverse side of the insulating warp-knitted fabric and connected to the positive and negative electrodes respectively.

[0081] Main circuit I consists of the left part of conductive yarn a and conductive yarn c in contact with it; branch circuit I consists of the right part of conductive yarn a; main circuit II consists of the left rear part of conductive yarn b, conductive yarn d in contact with the left rear part, the right part of conductive yarn b, and conductive yarn e in contact with the right part; branch circuit II consists of the left front part of conductive yarn b.

[0082] The conductive yarn f is in contact with both branch circuit I and branch circuit II simultaneously;

[0083] Multiple conductive yarns Y are woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (chain-forming) manner; multiple conductive yarns e are woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (chain-forming) manner; conductive yarn f is woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (warp-flat) manner.

[0084] The preparation method for the integrally formed multilayer flexible fabric circuit described above is as follows: A single-needle bed warp knitting machine with two large horizontal pattern combs and three ground combs is used for knitting. The order of the combs from front to back of the machine is: GB1 (ground comb), GB2 (ground comb), GB3 (ground comb), PB1 (large horizontal pattern comb), PB2 (large horizontal pattern comb). During the knitting process, GB1 forms the warp, GB2 acts as the warp insert, GB3 acts as the weft insert with one stitch, and PB1 and PB2 perform the weft insert movement according to the trajectory shown in Figure 3. Then, the knitted fabric is removed from the machine, and the conductive yarn Y is cut as shown in Figure 3. Electrodes are then connected to obtain the integrally formed multilayer flexible fabric circuit. Specifically, GB1 is fully threaded with insulating yarn, GB2 has 30 conductive yarns X on each side, GB3 has fully threaded with conductive yarn f, PB1 has one conductive yarn a, and PB2 has one conductive yarn b. Example 4

[0085] An integrally formed multi-layer flexible fabric circuit, classified by functional layout, includes main circuit I, branch circuit I, main circuit II, and branch circuit II. Main circuit I is connected to branch circuit I, main circuit II is connected to branch circuit II, main circuit I is not connected to main circuit II, and branch circuit I is not connected to branch circuit II;

[0086] Main circuit I and main circuit II enclose a "匚"-shaped area, and both branch circuit I and branch circuit II are located within this area;

[0087] The resistance ratio of main circuit I to branch circuit I is 15, and the resistance ratio of main circuit II to branch circuit II is 15;

[0088] Classified by composition structure, it consists of an insulating warp knitted fabric (made of insulating yarns, the insulating yarns are flame-retardant polyester with a specification of 100D / 48F), electrodes located on the surface of the insulating warp knitted fabric, and single conductive yarn a (the linear resistance of conductive yarn a is 0.04Ω / cm, and conductive yarn a is twisted from 9 copper wires with a diameter of 0.03mm), single conductive yarn b (the linear resistance of conductive yarn b is 0.04Ω / cm, and conductive yarn b is twisted from 9 copper wires with a diameter of 0.03mm), conductive yarn X, and conductive yarn f (conductive yarn f is pre-oxidized yarn low-temperature carbonized with a linear resistance of 5000Ω / cm);

[0089] Conductive yarn a is a weft yarn inserted into the insulating warp knitted fabric from the left side and consists of left and right parts;

[0090] Conductive yarn b is a weft yarn inserted into the insulating warp knitted fabric from the right side and consists of left and right parts. The left part is divided into a left front part and a left rear part arranged along the warp direction;

[0091] Conductive yarn a is located in front of the left rear part of conductive yarn b;

[0092] Conductive yarn X is composed of multiple conductive yarns c, multiple conductive yarns d, and multiple (30) conductive yarns e (conductive yarn e is a copper wire with a diameter of 0.03mm, twisted from 9 wires, and the linear resistance is 0.04Ω / cm);

[0093] Multiple conductive yarns c and multiple conductive yarns d respectively correspond to the front and rear segments arranged along the warp direction formed after multiple (30) conductive yarns Y (conductive yarn Y is a copper wire with a diameter of 0.03mm, twisted from 9 wires, and the linear resistance is 0.04Ω / cm) are cut. One end of multiple conductive yarns c and multiple conductive yarns d exposes from the process reverse side of the insulating warp knitted fabric and is respectively connected to the positive and negative electrodes;

[0094] Main circuit I consists of the left part of conductive yarn a and conductive yarn c in contact with it; branch circuit I consists of the right part of conductive yarn a; main circuit II consists of the left rear part of conductive yarn b, conductive yarn d in contact with the left rear part, the right part of conductive yarn b, and conductive yarn e in contact with the right part; branch circuit II consists of the left front part of conductive yarn b.

[0095] The conductive yarn f is in contact with both branch circuit I and branch circuit II simultaneously;

[0096] Multiple conductive yarns Y are woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (log-forming method is warp flat) manner; multiple conductive yarns e are woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (log-forming method is warp flat) manner; conductive yarn f is woven into the loops and extensions of the insulating warp-knitted fabric in a loop-forming (log-forming method is chain braiding) manner.

[0097] The preparation method for the integrally formed multilayer flexible fabric circuit described above is as follows: A single-needle bed warp knitting machine with two large horizontal pattern combs and three ground combs is used for knitting. The order of the combs from front to back of the machine is: GB1 (ground comb), GB2 (ground comb), GB3 (ground comb), PB1 (large horizontal pattern comb), PB2 (large horizontal pattern comb). During the knitting process, GB1 forms the warp, GB2 acts as the warp insert, GB3 acts as the weft insert with one stitch, and PB1 and PB2 perform the weft insert movement according to the trajectory shown in Figure 3. Then, the knitted fabric is removed from the machine, and the conductive yarn Y is cut as shown in Figure 3. Electrodes are then connected to obtain the integrally formed multilayer flexible fabric circuit. Specifically, GB1 is fully threaded with insulating yarn, GB2 has 30 conductive yarns X on each side, GB3 has fully threaded with conductive yarn f, PB1 has one conductive yarn a, and PB2 has one conductive yarn b. Example 5

[0098] A one-piece molded multilayer flexible fabric circuit comprises an insulating weft-knitted double-sided fabric (composed of insulating yarn, which is polyacrylonitrile pre-oxidized yarn with a specification of 40s), electrodes located on the surface of the insulating weft-knitted double-sided fabric, and simultaneously located inside the insulating weft-knitted double-sided fabric are a single conductive yarn g (the conductive yarn g has a linear resistance of 0.04Ω / cm and is made of 9 copper wires with a diameter of 0.03mm twisted together), a single conductive yarn h (the conductive yarn h has a linear resistance of 0.04Ω / cm and is made of 9 copper wires with a diameter of 0.03mm twisted together), and a conductive yarn i (the conductive yarn i is polyester fiber coated with carbon nanotube conductive paste, with a specification of 70D and a linear resistance of 2000Ω / cm).

[0099] Conductive yarn g and conductive yarn h do not come into contact;

[0100] One end of conductive yarn g and conductive yarn h protrudes from the same side of the insulating weft-knitted double-sided fabric and is connected to the positive and negative electrodes, respectively.

[0101] The conductive yarn g is divided into two parts, left and right. The left part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The right part is a floating yarn. The left part constitutes the main circuit III and the right part constitutes the branch circuit III.

[0102] The conductive yarn h is divided into two parts, left and right. The right part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The left part is a floating yarn. The right part constitutes the main circuit IV, and the left part constitutes the branch circuit IV.

[0103] The resistance ratio of main circuit III to branch circuit III is 6, and the resistance ratio of main circuit IV to branch circuit IV is 6.

[0104] Conductive yarn i is in contact with both branch circuit III and branch circuit IV simultaneously;

[0105] Conductive yarn i is woven into the front and back loops of the insulating weft-knitted double-sided fabric by adding yarn to form loops.

[0106] The preparation method for the integrally molded multilayer flexible fabric circuit described above is as follows: On an 18-gauge computerized flat knitting machine, four yarn feeders are used to knit an electrically heated fabric. The yarn feeders from left to right are YG1, YG2, YG3, and YG4. YG1 and YG2 knit a ribbed weave on the left side of the fabric, YG1 and YG3 knit a ribbed weave in the middle of the fabric, and YG1 and YG4 knit a ribbed weave on the right side of the fabric. YG2 and YG4 are respectively introduced into the yarn i region via floats, thus connecting the electrodes. YG1 is threaded with insulating yarn, YG2 with conductive yarn g, YG3 with conductive yarn i, and YG4 with conductive yarn h. Example 6

[0107] A one-piece molded multilayer flexible fabric circuit comprises an insulating weft-knitted double-sided fabric (composed of insulating yarn, which is flame-retardant nylon filament with a specification of 100D / 48F), electrodes located on the surface of the insulating weft-knitted double-sided fabric, and simultaneously located inside the insulating weft-knitted double-sided fabric are a single conductive yarn g (the conductive yarn g has a linear resistance of 0.025Ω / cm, and the conductive yarn g is made of 12 copper wires with a diameter of 0.03mm twisted together), a single conductive yarn h (the conductive yarn h has a linear resistance of 0.025Ω / cm, and the conductive yarn g is made of 12 copper wires with a diameter of 0.03mm twisted together), and a conductive yarn i (the conductive yarn i is pre-oxidized yarn carbonized at low temperature, with a linear resistance of 3000Ω / cm).

[0108] Conductive yarn g and conductive yarn h do not come into contact;

[0109] One end of conductive yarn g and conductive yarn h protrudes from the same side of the insulating weft-knitted double-sided fabric and is connected to the positive and negative electrodes, respectively.

[0110] The conductive yarn g is divided into two parts, left and right. The left part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The right part is a floating yarn. The left part constitutes the main circuit III and the right part constitutes the branch circuit III.

[0111] The conductive yarn h is divided into two parts, left and right. The right part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The left part is a floating yarn. The right part constitutes the main circuit IV, and the left part constitutes the branch circuit IV.

[0112] The resistance ratio of main circuit III to branch circuit III is 8, and the resistance ratio of main circuit IV to branch circuit IV is 8.

[0113] Conductive yarn i is in contact with both branch circuit III and branch circuit IV simultaneously;

[0114] Conductive yarn i is woven into the front and back loops of the insulating weft-knitted double-sided fabric by adding yarn to form loops.

[0115] The preparation method for the integrally molded multilayer flexible fabric circuit described above is as follows: On an 18-gauge computerized flat knitting machine, four yarn feeders are used to knit an electrically heated fabric. The yarn feeders from left to right are YG1, YG2, YG3, and YG4. YG1 and YG2 knit a ribbed weave on the left side of the fabric, YG1 and YG3 knit a ribbed weave in the middle of the fabric, and YG1 and YG4 knit a ribbed weave on the right side of the fabric. YG2 and YG4 are respectively introduced into the yarn i region via floats, thus connecting the electrodes. YG1 is threaded with insulating yarn, YG2 with conductive yarn g, YG3 with conductive yarn i, and YG4 with conductive yarn h. Example 7

[0116] A one-piece molded multilayer flexible fabric circuit comprises an insulating weft-knitted double-sided fabric (composed of insulating yarn, which is wool yarn with a specification of 60 Nm), electrodes located on the surface of the insulating weft-knitted double-sided fabric, and simultaneously located inside the insulating weft-knitted double-sided fabric are a single conductive yarn g (the conductive yarn g has a linear resistance of 0.015 Ω / cm, and the conductive yarn g is made of 7 copper wires with a diameter of 0.05 mm twisted together), a single conductive yarn h (the conductive yarn h has a linear resistance of 0.015 Ω / cm, and the conductive yarn h is made of 7 copper wires with a diameter of 0.05 mm twisted together), and a conductive yarn i (the conductive yarn i is pre-oxidized yarn carbonized at low temperature, with a linear resistance of 5000 Ω / cm).

[0117] Conductive yarn g and conductive yarn h do not come into contact;

[0118] One end of conductive yarn g and conductive yarn h protrudes from the same side of the insulating weft-knitted double-sided fabric and is connected to the positive and negative electrodes, respectively.

[0119] The conductive yarn g is divided into two parts, left and right. The left part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The right part is a floating yarn. The left part constitutes the main circuit III and the right part constitutes the branch circuit III.

[0120] The conductive yarn h is divided into two parts, left and right. The right part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The left part is a floating yarn. The right part constitutes the main circuit IV, and the left part constitutes the branch circuit IV.

[0121] The resistance ratio of main circuit III to branch circuit III is 10, and the resistance ratio of main circuit IV to branch circuit IV is 10.

[0122] Conductive yarn i is in contact with both branch circuit III and branch circuit IV simultaneously;

[0123] Conductive yarn i is woven into the front and back loops of the insulating weft-knitted double-sided fabric by adding yarn to form loops.

[0124] The preparation method for the integrally molded multilayer flexible fabric circuit described above is as follows: On an 18-gauge computerized flat knitting machine, four yarn feeders are used to knit an electrically heated fabric. The yarn feeders from left to right are YG1, YG2, YG3, and YG4. YG1 and YG2 knit a ribbed weave on the left side of the fabric, YG1 and YG3 knit a ribbed weave in the middle of the fabric, and YG1 and YG4 knit a ribbed weave on the right side of the fabric. YG2 and YG4 are respectively introduced into the yarn i region via floats, thus connecting the electrodes. YG1 is threaded with insulating yarn, YG2 with conductive yarn g, YG3 with conductive yarn i, and YG4 with conductive yarn h. Example 8

[0125] A one-piece molded multilayer flexible fabric circuit comprises an insulating weft-knitted double-sided fabric (composed of insulating yarn, which is flame-retardant polyester with a specification of 100D / 48F), electrodes located on the surface of the insulating weft-knitted double-sided fabric, and simultaneously located inside the insulating weft-knitted double-sided fabric a single conductive yarn g (the conductive yarn g has a linear resistance of 0.04Ω / cm, and is made of 7 copper wires with a diameter of 0.03mm twisted together), a single conductive yarn h (the conductive yarn h is a copper wire with a diameter of 0.03mm, made of 9 twisted together, and has a linear resistance of 0.04Ω / cm), and a conductive yarn i (the conductive yarn i is pre-oxidized yarn carbonized at low temperature, and has a linear resistance of 5000Ω / cm).

[0126] Conductive yarn g and conductive yarn h do not come into contact;

[0127] One end of conductive yarn g and conductive yarn h protrudes from the same side of the insulating weft-knitted double-sided fabric and is connected to the positive and negative electrodes, respectively.

[0128] The conductive yarn g is divided into two parts, left and right. The left part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The right part is a floating yarn. The left part constitutes the main circuit III and the right part constitutes the branch circuit III.

[0129] The conductive yarn h is divided into two parts, left and right. The right part is woven into the front and back loops of the insulating weft knitted double-sided fabric by adding yarn to form loops. The left part is a floating yarn. The right part constitutes the main circuit IV, and the left part constitutes the branch circuit IV.

[0130] The resistance ratio of main circuit III to branch circuit III is 10, and the resistance ratio of main circuit IV to branch circuit IV is 10.

[0131] Conductive yarn i is in contact with both branch circuit III and branch circuit IV simultaneously;

[0132] Conductive yarn i is woven into the front and back loops of the insulating weft-knitted double-sided fabric by adding yarn to form loops.

[0133] The preparation method for the integrally molded multilayer flexible fabric circuit described above is as follows: On an 18-gauge computerized flat knitting machine, four yarn feeders are used to knit an electrically heated fabric. The yarn feeders from left to right are YG1, YG2, YG3, and YG4. YG1 and YG2 knit a ribbed weave on the left side of the fabric, YG1 and YG3 knit a ribbed weave in the middle of the fabric, and YG1 and YG4 knit a ribbed weave on the right side of the fabric. YG2 and YG4 are respectively introduced into the yarn i region via floats, thus connecting the electrodes. YG1 is threaded with insulating yarn, YG2 with conductive yarn g, YG3 with conductive yarn i, and YG4 with conductive yarn h.

Claims

1. A one-piece molded multilayer flexible fabric circuit, characterized in that, The classification by functional layout includes main circuit I, branch circuit I, main circuit II, and branch circuit II. Main circuit I is connected to branch circuit I, and main circuit II is connected to branch circuit II. Main circuit I is not connected to main circuit II, and branch circuit I is not connected to branch circuit II. Main circuit I and main circuit II enclose a "匚"-shaped area, and both branch circuit I and branch circuit II are located within this area. The resistance ratio of main circuit I to branch circuit I is not less than 6, and the resistance ratio of main circuit II to branch circuit II is not less than 6. The classification by composition structure includes an insulating warp knitted fabric and a single conductive yarn a, a single conductive yarn b, and multiple conductive yarns X located inside it at the same time. Conductive yarn a is a weft yarn inserted into the insulating warp knitted fabric from the left side, and conductive yarn b is a weft yarn inserted into the insulating warp knitted fabric from the right side. Main circuit I is composed of a part of conductive yarn a and a part of conductive yarn X in contact with it, branch circuit I is composed of another part of conductive yarn a, main circuit II is composed of a part of conductive yarn b and another part of conductive yarn X in contact with it, and branch circuit II is composed of another part of conductive yarn b.

2. The integrally molded multilayer flexible fabric circuit according to claim 1, characterized in that, The multiple conductive yarns X include multiple conductive yarns c, multiple conductive yarns d, and multiple conductive yarns e. Multiple conductive yarns c and multiple conductive yarns d respectively correspond to the front segment and the rear segment arranged along the warp direction formed after multiple conductive yarns Y are cut. One end of both multiple conductive yarns c and multiple conductive yarns d exposes from the technical reverse side of the insulating warp knitted fabric. Conductive yarn a is divided into left and right parts; conductive yarn b is divided into left and right parts, and the left part of conductive yarn b is divided into a left front part and a left rear part arranged along the warp direction; conductive yarn a is located in front of the left rear part of conductive yarn b. Main circuit I is composed of the left part of conductive yarn a and conductive yarn c in contact with it, branch circuit I is composed of the right part of conductive yarn a, main circuit II is composed of the left rear part of conductive yarn b, conductive yarn d in contact with the left rear part, the right part of conductive yarn b, and conductive yarn e in contact with the right part, and branch circuit II is composed of the left front part of conductive yarn b.

3. The integrally molded multilayer flexible fabric circuit according to claim 2, characterized in that, Multiple conductive yarns Y are woven into the loop and the extension line of the insulating warp knitted fabric in the form of warp insertion, weft insertion, or looping; multiple conductive yarns e are woven into the loop and the extension line of the insulating warp knitted fabric in the form of warp insertion, weft insertion, or looping.

4. The integrally molded multilayer flexible fabric circuit according to claim 3, characterized in that, All looping methods are selected from one of chain stitch, plain stitch, plush stitch, and cross stitch.

5. The integrally molded multilayer flexible fabric circuit according to claim 2, characterized in that, The classification by composition structure also includes an electrode located on the surface of the insulating warp knitted fabric. One end of multiple conductive yarns c and multiple conductive yarns d exposed from the insulating warp knitted fabric are respectively connected to the positive and negative electrodes.

6. The integrally molded multilayer flexible fabric circuit according to claim 1, characterized in that, The classification by composition structure also includes a conductive yarn f located inside the insulating warp knitted fabric. Conductive yarn f is in contact with both branch circuit I and branch circuit II at the same time; conductive yarn f is woven into the loop and the extension line of the insulating warp knitted fabric in the form of warp insertion, weft insertion, or looping; the linear resistance of conductive yarn f is 100 - 5000 Ω / cm, and the linear resistance of conductive yarn a and conductive yarn b is 0.01 - 1 Ω / cm.

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