Multi-material fibers and methods of manufacturing the same

1. A method of manufacturing a multi-material fiber comprising at least one electrically-connectable device, the method comprising the steps of:

positioning each electrically-connectable device within a corresponding pocket provided in a preform material;

positioning a first electrical conductor longitudinally within a first conduit provided in the preform material; and

drawing the multi-material fiber by causing the preform material to flow, such that the first electrical conductor extends within the multi-material fiber along a longitudinal axis thereof and makes an electrical contact with a first electrode located on each electrically-connectable device,

wherein, after drawing the multi-material fiber, (i) the first electrode located on each electrically-connectable device faces a neutral axis of the multi-material fiber, (ii) the first electrical conductor is located substantially along the neutral axis of the multi-material fiber, and (iii) a metallurgical bond is formed substantially at the neutral axis of the multi-material fiber between the first electrical conductor and the first electrode located on each electrically-connected device.

2. The method of claim 1 , further comprising positioning a second electrical conductor longitudinally within a second conduit provided in the preform material.

3. The method of claim 2 , wherein drawing the multi-material fiber by causing the preform material to flow further causes the second electrical conductor to extend within the multi-material fiber along the longitudinal axis thereof and to make an electrical contact with a second electrode located on each electrically-connectable device.

4. The method of claim 3 , wherein a metallurgical bond is formed between the second electrical conductor and the second electrode while drawing the multi-material fiber.

5. The method of claim 3 , wherein, after drawing the multi-material fiber, the second electrical conductor is located substantially along the neutral axis of the multi-material fiber.

6. The method of claim 1 , wherein positioning the first electrical conductor comprises positioning a copper alloy wire within the first conduit.

7. The method of claim 6 , wherein the copper alloy wire comprises a silver coating.

8. The method of claim 1 , further comprising depositing a bonding material on the first electrode prior to drawing the multi-material fiber.

9. The method of claim 8 , wherein the bonding material comprises a metal alloy material.

10. The method of claim 9 , wherein the metal alloy material comprises tin and bismuth.

11. The method of claim 8 , wherein a melting point of the bonding material substantially matches a glass transition temperature of the preform material.

12. The method of claim 8 , wherein depositing the bonding material on the first electrode utilizes a hot press device.

13. The method of claim 1 , further comprising controlling an aspect ratio of the drawn multi-material fiber.

14. The method of claim 13 , wherein the controlled aspect ratio is between about 1.1:1 and about 2.7:1.

15. The method of claim 13 , wherein controlling the aspect ratio comprises adding sidewalls to the drawn multi-material fiber.

16. The method of claim 1 , further comprising overcoating the drawn multi-material fiber.

17. The method of claim 16 , wherein the drawn multi-material fiber is overcoated with a thermoplastic elastomer material.

18. The method of claim 1 , further comprising positioning a support wire longitudinally within an additional conduit in the preform material to provide mechanical stability to each electrically-connectable device.

19. The method of claim 18 , wherein positioning the support wire comprises positioning the support wire within the additional conduit such that, after the multi-material fiber is drawn, the support wire contacts each electrically-connectable device without making electrical contact with the first electrical conductor or the first electrode.

20. The method of claim 1 , further comprising positioning at least one outer wire longitudinally within a corresponding conduit in the preform material.

21. The method of claim 20 , wherein positioning the at least one outer wire comprises positioning each outer wire so that, after drawing the multi-material fiber, each outer wire is located substantially along the neutral axis of the drawn multi-material fiber.

22. The method of claim 1 , further comprising interlacing the drawn multi-material fiber with a plurality of additional fibers to form a textile.

23. The method of claim 22 , further comprising adding rigidity to the textile.

24. The method of claim 23 , wherein adding rigidity to the textile comprises at least one of:

adding tubing to the textile;

adding a plurality of stiffeners to the textile;

adding a backing to the textile; or

adding a ribbon-cable backing to the textile.

25. The method of claim 22 , further comprising at least one of:

wrapping the drawn multi-material fiber with an overwrap prior to the interlacing; or

producing a composite yarn comprising at least one of a high modulus mono-filament yarn, a high strength mono-filament yarn, a high modulus multi-filament yarn, or a high strength multi-filament yarn placed in parallel with the drawn multi-material fiber; and

overwrapping the composite yarn with at least one of similar or other textile yarns.

26. The method of claim 25 , wherein the overwrap comprises a plurality of high tensile strength fibers.

27. The method of claim 26 , wherein the high tensile strength fibers comprise one or more of aramids, dyneema, or basalt fibers.

28. A textile comprising:

(i) a multi-material fiber comprising:

a cladding material;

an electrically-connectable device disposed within the cladding material; and

a first electrical conductor disposed within the cladding material and in electrical communication with a first electrode on the electrically-connectable device; and

(ii) a plurality of additional fibers interlaced with the multi-material fiber,

wherein, (i) the first electrode on the electrically-connectable device faces a neutral axis of the multi-material fiber, (ii) the first electrical conductor is located substantially along the neutral axis of the multi-material fiber, and (iii) the first electrical conductor is in electrical communication with the first electrode via a first metallurgical bond formed substantially at the neutral axis of the multi-material fiber, the first metallurgical bond comprising a bonding material having a melting temperature that substantially matches a glass transition temperature of the cladding material.

29. The textile of claim 28 , wherein the multi-material fiber further comprises a second electrical conductor disposed within the cladding material and in electrical communication with a second electrode on the electrically-connectable device.

30. The textile of claim 29 , wherein the second electrical conductor is in electrical communication with the second electrode via a second metallurgical bond that comprises a bonding material having a melting temperature that substantially matches the glass transition temperature of the cladding material.

31. The textile of claim 29 , wherein the second electrical conductor is located substantially along the neutral axis of the multi-material fiber.

32. The textile of claim 28 , wherein the cladding material is selected from the group consisting of a thermoplastic material, a thermoplastic elastomer, and glass.

33. The textile of claim 28 , wherein the electrically-connectable device is selected from the group consisting of a light-emitting diode, a light-emitting device, a microphone, an inertial measurement unit, an interposer, an interconnect device, a temperature sensor, a light-responsive device, a photodetector, and a photodiode.

34. The textile of claim 28 , wherein the bonding material comprises a metal alloy material.

35. The textile of claim 34 , wherein the metal alloy material comprises a solder made of tin and bismuth.

36. The textile of claim 28 , wherein the first electrical conductor is selected from the group consisting of a copper wire, a copper wire comprising a silver coating, a tungsten wire, a high tension wire, and an extra high tension wire.

37. The textile of claim 28 , wherein the multi-material fiber has an aspect ratio between about 1.1:1 and about 2.7:1.

38. The textile of claim 28 , wherein the multi-material fiber comprises an overcoating.

39. The textile of claim 38 , wherein the overcoating comprises a thermoplastic elastomer material.

40. The textile of claim 28 , wherein the multi-material fiber comprises an overwrap.

41. The textile of claim 40 , wherein the overwrap comprises a plurality of high tensile strength fibers.

42. The textile of claim 41 , wherein the high tensile strength fibers comprise one or more of aramids, dyneema, or basalt fibers.

43. The textile of claim 28 , wherein the multi-material fiber further comprises a support wire to provide mechanical stability to the device.

44. The textile of claim 28 , wherein the multi-material fiber further comprises at least one outer wire.

45. The textile of claim 44 , wherein the outer wire is located substantially along the neutral axis of the multi-material fiber.

46. The textile of claim 44 , wherein the outer wire comprises one or more of a wire made from aramid, dyneema, or tungsten.