IP Library › Granted Patent US 11,891,729

Granted Patent B2

US 11,891,729 · App. 16/845,796 · Granted Feb 6, 2024

Machine-knittable conductive hybrid yarns

Inventors: Clare King (Providence, RI); Anjali Khemani (Providence, RI); Birgit Leitner (Providence, RI)

Assignee: Propel, LLC

D02G3/36 D02G3/045 D02G3/047 D02G3/12 D02G3/441 D02G3/443 A61B5/25 A61B5/27 A61B5/6804 A61B2562/14 D03D1/0088 D04B1/12 D04B1/126 D10B2211/02 D10B2401/16 D10B2403/02431 D10B2501/00 H05K1/038 H05K2201/0281

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Quick Facts

Patent No.: US 11,891,729
App. No.: 16/845,796
Granted: Feb 6, 2024
Kind: B2

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Abstract

A machine knittable hybrid yarn for providing conductive traces through a textile is disclosed. The hybrid yarn includes conductive wires coated with an insulating material and twisted together with a nonconductive yarn. The nonconductive yarn is from a strong, inelastic, and nonconductive fiber, such as a meta-aramid or para-aramid that protects the integrity of the conductive wire during knitting. The conductive wire can be copper-clad stainless steel or copper wire is coated with polyurethane, and the nonconductive yarn can have no-drip and no-drip properties to allow ablation of the hybrid yarn to remove the conductive yarn and insulating coating on the wire such that the ablated region becomes externally conductive and suitable for making an electrical contact. The hybrid yarn can be bonded with nylon or similar polymer after twisting.

Claims (191)

1. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch,

wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

2. The hybrid yarn of claim 1 , wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns with Z twist or an S twist from a single twisting process.

3. The hybrid yarn of claim 1 ,

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 5 and 12 twists per inch.

4. The hybrid yarn of claim 1 , wherein the two or more electrically conductive wires define a continuous strand of metal along the hybrid yarn.

5. The hybrid yarn of claim 1 , wherein the hybrid yarn is bonded with a polymer layer.

6. The hybrid yarn of claim 5 , wherein the hybrid yarn is bonded with Nylon.

7. The hybrid yarn of claim 1 , wherein the insulating material of the two or more electrically conductive wires comprises a polymer coating.

8. The hybrid yarn of claim 1 , wherein the two or more electrically conductive wires are approximately 10 to 100 microns thick.

9. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

10. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

11. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

12. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

13. The hybrid yarn of claim 1 ,

wherein the one or more electrically non-conductive yarns have a Young's modulus of at least 60 GPa.

14. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns comprise at least one of an aramid, meta-aramid, or para-aramid polyamide fiber.

15. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns comprise at least one: Ultra High Molecular Weight Polyethene (UHMWPE), Polybenzimidazole (PBI), Polyphenylene Benzobisoxazole (PBO), High Strength Polyester, Liquid-Crystal Polymer (LCP), or spider silk.

16. The hybrid yarn of claim 1 , wherein the two or more electrically conductive wires comprise a copper-clad stainless steel wire or a solid copper wire.

17. The hybrid yarn of claim 1 ,

wherein the one or more electrically non-conductive yarns and the insulating material each have a decomposition temperature greater than a melting point of the two or more electrically conductive wires.

18. The hybrid yarn of claim 1 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

19. The hybrid yarn of claim 1 ,

wherein the two or more electrically conductive wires are a first two electrically conductive wires, and

the hybrid yarn further comprises a third electrically conductive wire wrapped with the one or more electrically non-conductive yarns.

20. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns; and

two or more electrically conductive wires wrapped around the one or more electrically non-conductive yarns, the two or more electrically conductive wires having an exterior layer of an insulating material,

wherein the one or more electrically non-conductive yarns have a tensile strength higher than a tensile strength of the two or more electrically conductive wires,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the one or more electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

21. A method of making a machine-knittable hybrid yarn, the method comprising:

wrapping, in a single process, two or more electrically conductive wires around one or more electrically non-conductive yarns, the electrically conductive wires each having an exterior coated with an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn, and

wherein the one or more electrically non-conductive yarns comprise at least one: Ultra High Molecular Weight Polyethene (UHMWPE), Polybenzimidazole (PBI), Polyphenylene Benzobisoxazole (PBO), High Strength Polyester, Liquid-Crystal Polymer (LCP), or spider silk.

22. The method of claim 21 , further comprising:

bonding, after the wrapping, the wrapped one or more electrically non-conductive yarns and the two or more electrically conductive wires with an electrically non-conductive exterior layer.

23. The method of claim 22 ,

wherein the one or more electrically non-conductive later yarns comprises a polymer.

24. The method of claim 21 ,

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch.

25. The method of claim 21 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

26. The method of claim 21 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

27. The method of claim 21 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

28. The method of claim 21 ,

wherein the one or more electrically non-conductive yarns have a Young's modulus of at least 60 GPa.

29. The method of claim 21 ,

wherein the one or more electrically non-conductive yarns have a break elongation percentage of 4.2 or less.

30. The method of claim 21 , wherein the one or more electrically non-conductive yarns further comprise at least one of: an aramid, meta-aramid, or para-aramid polyamide fiber.

31. The method of claim 21 , wherein the two or more electrically conductive wires comprise a copper-clad stainless steel wire or a solid copper wire.

32. The method of claim 21 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

33. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns have a break elongation percentage of 4.2 or less.

34. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

35. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

36. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns comprise at least one of an aramid, meta-aramid, or para-aramid polyamide fiber.

37. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns and the insulating material each have a decomposition temperature greater than a melting point of the two or more electrically conductive wires.

38. The hybrid yarn of claim 20 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

39. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch; and

wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

40. The hybrid yarn of claim 39 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

41. The hybrid yarn of claim 39 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

42. The hybrid yarn of claim 39 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

43. The hybrid yarn of claim 39 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

44. The hybrid yarn of claim 39 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

45. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

46. The hybrid yarn of claim 45 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

47. The hybrid yarn of claim 45 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

48. The hybrid yarn of claim 45 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

49. The hybrid yarn of claim 45 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

50. The hybrid yarn of claim 45 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

51. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

52. The hybrid yarn of claim 51 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

53. The hybrid yarn of claim 51 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

54. The hybrid yarn of claim 51 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

55. The hybrid yarn of claim 51 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

56. The hybrid yarn of claim 51 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

57. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

58. The hybrid yarn of claim 57 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

59. The hybrid yarn of claim 57 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

60. The hybrid yarn of claim 57 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

61. The hybrid yarn of claim 57 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

62. The hybrid yarn of claim 57 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

63. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

wherein the one or more electrically non-conductive yarns comprise at least one of an aramid, meta-aramid, or para-aramid polyamide fiber.

64. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

65. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

66. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

67. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

68. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

69. The hybrid yarn of claim 63 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

70. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

71. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

72. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

73. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

74. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

75. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

76. The hybrid yarn of claim 70 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

77. A machine-knittable hybrid yarn, comprising:

one or more electrically non-conductive yarns;

two or more electrically conductive wires wrapped around the electrically non-conductive yarns, the electrically conductive wires having an exterior layer of an insulating material,

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn;

wherein the two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch, and

wherein the one or more electrically non-conductive yarns comprise staple fibers.

78. The hybrid yarn of claim 77 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

79. The hybrid yarn of claim 77 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

80. The hybrid yarn of claim 77 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

81. The hybrid yarn of claim 77 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

82. The hybrid yarn of claim 77 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

83. A method of making a machine-knittable hybrid yarn, the method comprising:

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

84. The method of claim 83 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

85. The method of claim 83 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

86. The method of claim 83 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

87. The method of claim 83 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

88. The method of claim 83 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

89. A method of making a machine-knittable hybrid yarn, the method comprising:

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

90. The method of claim 89 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

91. The method of claim 89 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

92. The method of claim 89 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

93. The method of claim 89 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

94. The method of claim 89 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

95. A method of making a machine-knittable hybrid yarn, the method comprising:

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

96. The method of claim 95 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

97. The method of claim 95 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

98. The method of claim 95 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

99. The method of claim 95 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

100. The method of claim 95 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

101. A method of making a machine-knittable hybrid yarn, the method comprising:

wherein the number of electrically non-conductive yarns is less than the number of electrically conductive wires;

wherein the electrically non-conductive yarns comprise a majority fraction of an overall cross-section of the hybrid yarn; and

wherein the one or more electrically non-conductive yarns comprise at least one of: an aramid, meta-aramid, or para-aramid polyamide fiber.

102. The method of claim 101 , wherein the one or more electrically non-conductive yarns are 1500 denier or finer.

103. The method of claim 101 , wherein the one or more electrically non-conductive yarns have an elasticity less than that of the wrapped two or more electrically conductive wires such that the two or more electrically conductive wires do not break before the one or more electrically non-conductive yarns under tensile loading of the hybrid yarn.

104. The method of claim 101 , wherein the one or more electrically non-conductive yarns are fire retardant and self-extinguishing.

105. The method of claim 101 , wherein the one or more electrically non-conductive yarns have a tensile strength higher than the two or more electrically conductive wires.

106. The method of claim 101 , wherein the one or more electrically non-conductive yarns comprise staple fibers.

107. The method of claim 101 , wherein the one or more electrically non-conductive yarns are no-melt and no-drip according to the ASTM D6413/D6413M Standard Vertical Test Method for Flame Resistance of Textiles.

Assignments (1)

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 17, 2023

From: KING, CLARE; KHEMANI, ANJALI; LEITNER, BIRGIT

To: PROPEL, LLC

Reel/Frame 065604/0014 →

Continuity (4)

Provisional Application 62832098 · Apr 10, 2019

Provisional Application 62832104 · Apr 10, 2019

Provisional Application 62832101 · Apr 10, 2019

Related Publication 20210277544A1 · Sep 9, 2021

Cited By (3)

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