# Patent

## Title
Garment with receptacle and electronic module

## Abstract

A garment includes a fabric portion with an electrode connected to the fabric portion and configured to engage a torso of the wearer. A receptacle is fixedly connected to the fabric portion and includes a receptacle housing, a socket defined by the receptacle housing, and an electrode lead, the electrode lead extending through the receptacle housing and providing an electrical connection between the electrode and the socket. An electronics module is configured to be removably inserted into the socket of the receptacle and contact the electrode lead. The electronics module includes a multi-component injection molded housing including a front face having a first portion and a second portion. The first portion is comprised of a relatively soft and resilient polymer material and the second portion is comprised of a relatively hard and rigid polymer material.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in part of U.S. patent application Ser. No. 13/629,207, filed Sep. 27, 2012, which claims priority from U.S. provisional patent application No. 61/539,687, filed Sep. 27, 2011.


FIELD
This application relates to the field of athletic apparel, and particularly to an electronic sensor arrangement on a garment or other an item of apparel.
BACKGROUND
Sensor arrangements are commonly used to monitor various physiological parameters such as heart rate, temperature, breathing rate, etc. These sensor arrangements typically include various electronics components including electrodes, microprocessors, power devices, wired or wireless communications interfaces, display devices, and related housings. While such sensor arrangements are often worn separate from the clothing of the monitored subject, it is increasingly common for such sensor arrangements to be incorporated into the clothing of the test subject. This allows the sensor arrangement to be quickly and conveniently positioned on the test subject for data collection. Placement of sensor arrangements on the garment of the test subject also tends to be more comfortable, as adhesives are not required to attach electrodes and other sensor arrangements to the skin of the test subject.
In sensor arrangements incorporated into articles of apparel, the electronics components are sometimes completely separable from the article of apparel. For example, some watches have included releasable electronics modules configured for placement in a socket provided on a wristband. The electronics module and associated display may then be easily moved to a socket provided on a different device such as an exercise machine. However, when such sensor arrangements with releasable electronics components are incorporated into a garment to be worn on the torso, the resulting arrangement is often bulky and uncomfortable for the wearer. Moreover, the releasable electronics modules are often difficult to connect to or separate from the garment, making use of the sensor arrangement inconvenient for the wearer.
In other sensor arrangements, the electronics components may be inseparable from the garment. For example, some shirts, chest straps or bras include electronics components that are incorporated into the garment such that the components cannot be removed from the garment without destruction of the garment. In these arrangements, critical electronics components such as the microprocessor, power device, and transmitter are potted in a polymer material that is fixed to the garment material. The polymer material seals the electronics components and prevents moisture intrusion. Accordingly, these garments are designed for washing by hand or a machine without destruction of the sensor arrangement provided on the garment. However, in the event of a small imperfection such as a crack or tear in the potting material, moisture may indeed seep into the potting material and short or otherwise destroy the electronics components of the electronics package. Such small imperfections may be the result of a manufacturing defect or wear of the garment and sensor arrangement over time.
In view of the foregoing, it would be desirable to provide a garment or other article of apparel including a sensor arrangement with a releasable electronics module that is comfortable for the wearer. It would be particularly advantageous if such electronics module could be quickly and easily released from or connected to the garment. Furthermore, it would be advantageous if such garment could be repeatedly washed without danger of damaging the sensitive electronics components in the electronics module.
SUMMARY
In accordance with one embodiment of the disclosure, there is provided a sensor arrangement comprising a garment and at least one electrode positioned on the garment. A multi-component injection molded receptacle is also provided on the garment. The multi-component injection molded receptacle includes a socket with a back wall, wherein a first part of the back wall is comprised of a relatively soft and resilient polymer material and a second part of the back wall is comprised of a relatively hard and rigid polymer material. The relatively soft and resilient polymer material is configured to flex substantially more than the relatively hard and rigid polymer material when a flex force from a human hand is applied to the receptacle. The receptacle further includes an electrode lead electrically connected between the at least one electrode and the socket. The sensor arrangement further includes a sensor module configured to be removably inserted into the socket of the receptacle and contact the electrode lead. The sensor module includes a multi-component injection molded housing including a front face having a first portion and a second portion. The first portion is comprised of the relatively soft and resilient polymer material and the second portion comprised of the relatively hard and rigid polymer material.
Pursuant to another embodiment of the disclosure, there is provided a garment configured to be worn on a torso of a wearer. The garment comprises a fabric portion configured to engage the torso of the wearer and an electrode fixedly connected to the fabric portion with the electrode configured to engage the torso of the wearer. The garment further comprises a receptacle fixedly connected to the fabric portion. The receptacle comprises a receptacle housing providing a socket. The receptacle housing includes an upper portion comprised of a relatively soft and resilient polymer material and a lower portion comprised of a relatively hard and rigid polymer material. The relatively soft and resilient polymer material is configured to flex substantially more than the relatively hard and rigid polymer material when a flex force from the wearer is applied to the receptacle. An electrode lead is positioned within the receptacle and provides an electrical connection between the electrode and the socket. An electronics module is releasably positioned in the socket. The electronics module includes a module housing with a module contact retained by the module housing. The electronics module further comprises a processor, a power device, and a transmitter positioned within the module housing. The module contact is electrically connected to the electrode lead when the electronics module is positioned in the socket.
In accordance with yet another embodiment of the disclosure, there is provided a garment configured to be worn on a torso of a wearer. The garment comprises a fabric portion configured to engage the torso of the wearer. An electrode is fixedly connected to the fabric portion and is configured to engage the torso of the wearer. A receptacle is fixedly connected to the fabric portion. The receptacle comprises a receptacle housing, a socket defined by the receptacle housing, and an electrode lead, the electrode lead extending through the receptacle housing and providing an electrical connection between the electrode and the socket. An electronics module is configured to be removably inserted into the socket of the receptacle and contact the electrode lead. The electronics module includes a multi-component injection molded housing including a front face, the front face including a first portion and a second portion, the first portion comprised of a relatively soft and resilient polymer material and the second portion comprised of a relatively hard and rigid polymer material.
The above described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. While it would be desirable to provide a garment with a sensor connection arrangement that provides one or more of these or other advantageous features, the teachings disclosed herein extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned advantages.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a front outside view of a garment with a sensor arrangement including a releasable electronics module;
FIG. 1B shows a front inside view of the garment of FIG. 1A;
FIG. 2 shows a cross-sectional view of the garment along line II-II of FIG. 1B;
FIG. 3 shows an rear view of a sensor band including receptacle and electrodes in isolation from the garment of FIG. 1B;
FIG. 4 shows a front perspective view of an electrode lead of the receptacle in engagement with the electrode of FIG. 3;
FIG. 5 shows an enlarged rear view of the electrode lead of FIG. 4 positioned in the receptacle;
FIG. 6 shows a front perspective view of the receptacle of FIG. 3;
FIG. 7 shows a front perspective view of an electronics module configured for placement in the receptacle of FIG. 6; and
FIG. 8 shows a front view of the electronics module of FIG. 7;
FIG. 9 shows a cross-sectional view of the electronics module through line IX-IX of FIG. 8;
FIG. 10A shows a front view of an alternative embodiment of the electronics module of FIG. 7;
FIG. 10B shows a rear view of the electronics module of FIG. 10A;
FIG. 10C shows a top view of the electronics module of FIG. 10A;
FIG. 10D shows a side view of the electronics module of FIG. 10A;
FIG. 11 shows a front view of an alternative embodiment of the receptacle of FIG. 3;
FIG. 12A shows a garment in the form of a strap with the electronics module of FIG. 10A mounted in the receptacle;
FIG. 12B shows a side view of the strap and electronics module of FIG. 12A; and
FIG. 12C shows a rear view of the strap of FIG. 12A.



DESCRIPTION
With reference to FIGS. 1A and 1B, a garment 10 is comprised of fabric portions 12 with a sensor arrangement 14 attached to one of the fabric portions 12. The sensor arrangement 14 includes electrodes 16 electrically connected to a receptacle 20, with the electrodes 16 and the receptacle 20 bonded to the garment 10 in a non-removable manner. An electronics module 22 is removably connected to the receptacle 20.
Electrodes on Garment
The fabric portions 12 of the garment may include a plurality of fabric panels connected together to form the garment. In the embodiment of FIGS. 1A and 1B, the fabric panels form a shirt and include a front panel 24 and a rear panel 26 that provide a torso portion 28 for the garment. The torso portion 28 includes a neck opening 30, arm openings 32, and a waist opening 34. While a shirt is disclosed as the garment in the embodiment of FIGS. 1A and 1B, it will be recognized by those of ordinary skill in the art that the garment may take other forms in other embodiments. For example, as described in further detail below, in at least one embodiment, the garment is a chest strap.
With continued reference to FIG. 1A, the receptacle 20 of the sensor arrangement 14 is positioned near a central location on the front of the torso portion 28 that corresponds to a location near the heart of a wearer, such as a chest portion of the garment 10. Similarly, as shown in FIG. 1B, the electrodes 16 of the sensor arrangement are positioned on the inside of the torso portion 28 at the chest portion, with the two electrodes 16 located on opposite sides of the receptacle 20.
The electrodes 16 are included on a sensor band 36 that extends laterally along the inside of the torso portion. The electrodes 16 include sensing pads 38 and conductive elements, such as conductive fibers 40 (see FIGS. 2 and 3) that connect the sensor pads 38 to the receptacle 20. As shown in FIG. 1B, the sensing pads 38 are exposed on the interior surface of the garment 10 and are configured to detect electrical signals on the skin of a wearer, such as heart rate or ECG signals, as will be recognized by those of ordinary skill in the art. The sensing pads 38 are connected to the conductive fibers 40 that extend laterally along the sensor band 36 and are configured to deliver electrical signals from the sensing pads 38 to the receptacle 20. The conductive fibers 40 may be any of various electrically conductive elements, including metal wire or electrically conductive textile fibers, such as silver coated elastane fibers.
As shown in FIG. 2, the conductive fibers 40 are generally positioned between an inner fabric layer 42 and an outer fabric layer 44 of the sensor band 36, thus shielding the conductive fibers 40 from electrical noise. Either the inner fabric layer 42 or the outer fabric layer 44 may be provided as a strip of fabric that only covers the sensor band 36, while leaving the inner sensing pads 38 exposed. An intermediate layer 43 may also be positioned between the inner fabric layer 42 and the outer fabric layer 44. However, it will be recognized that various alternative embodiments are also possible. For example, the conductive fibers 40 may be woven or otherwise integrated into a single textile layer on the garment. Furthermore, the layers need not be fabrics or textiles, and in at least one alternative embodiment, one or more of the layers are comprised of a polymer material.
FIG. 3 shows a rear view of the electrodes 16 (i.e., a view from inside of the garment 10) with the electrode 16 isolated from the fabric layers 42, 44 of the garment 10. The electrodes 16 include a first electrode 16a and a second electrode 16b positioned on opposite sides of the receptacle 20. Accordingly, the first electrode 16a and the second electrode 16b are electrically separated from one another on the garment 10. A measurable potential difference is thus produced between the first electrode 16a and the second electrode 16b (e.g., an ECG signal which is measured with the electronics components within the electronics module 22).
Electrode Coupling to Receptacle
With continued reference now to FIG. 3, the electrodes 16 are coupled to the rear side of the receptacle 20 via two electrode leads 50 retained within a receptacle housing 70. In particular, the two electrode leads 50 are crimped to the electrodes 16 to establish an electrical connection between the electrodes 16 and the electrode leads 50. The electrodes 16 are coupled to the leads 50 near a middle of the receptacle 20 (i.e., about half way between vertical top and vertical bottom of the receptacle when oriented as shown in FIG. 3). Accordingly, both the electrodes 16 and the leads 50 are centrally located at the side perimeter portions on the rear side of the receptacle housing 70. This arrangement is advantageous for manufacture of the sensor arrangement 14, allowing the electrodes to be easily coupled to the sides of the receptacle 20 without the need to extend further into the receptacle. In the disclosed embodiment, the electrodes only extend a few millimeters past the rear edges of the receptacle housing before they come into contact with the leads 50.
As best shown in FIG. 4, each electrode lead 50 includes a rear plate 52, two electrode connectors in the form of peripheral tangs 54 extending from one side of the rear plate 52, and a leaf spring 60 extending from the opposite side of the rear plate 52. The two peripheral tangs 54 provide are generally E-shaped members with longer outer arms 56 and a shorter center arm 58 connected along a spine 59. The ends of the longer outer arms 56 are connected to the rear plate 52 and the end of the shorter center arm 58 is free from the rear plate. Each tang 54 extends through a hole 46 in the electrode 16. The longer arms 56 of the tang 54 are bent to an extent that the spine 59 engages the surface of the electrode. In particular, each tang 54 is fastened to the electrode by crimping the tang 54 to the electrode with a strong force during assembly such that the rear plate 52 closely engages the rear surface of the electrode 16 and the E-shaped tangs 54 closely engage the front surface of the electrode 16. As a result, each electrode 16 is fastened to an associated electrode lead 50, and a firm electrical and mechanical connection is established between each electrode 16 and the associated electrode lead 50. Additionally, to further establish a good connection between each electrode 16 and the associated electrode lead 50, in at least one embodiment a thin layer of conductive adhesive is provided between the electrode 16 and the rear plate 52 and/or the tangs 54 of the electrode lead 50. Moreover, although not shown in FIG. 4, the tangs 54 may include sharp edges or other elements to provide for solid and continuous contact to the material forming the electrode 16.
With continued reference to FIG. 4, the leaf spring 60 is provided on an opposite side of the electrode lead 50 from the tangs 54. The leaf spring 60 includes a bend portion 62 with an elongated curved finger 64 extending from the bend portion. The bend portion 62 connects the leaf spring 60 to the rear plate 52 and generally orients the leaf spring 60 about 90° relative to the rear plate 52. The finger 64 flares away from the rear plate 52 as moving toward an end 66 of the finger 64.
With reference now to FIG. 5, an enlarged view of the electrode lead 50 is shown positioned in the receptacle housing 70. The receptacle housing 70 generally provides a structure to retain the various components of the receptacle 20, including the electrode leads 50 and receptacle contacts 80 provided by connection pins (also referenced herein as reference numeral 80). The receptacle housing 70 is comprised of a non-conductive, durable and relatively resilient polymer material, such as polyethylene, polypropylene, polyurethane, poly-vinyl chloride or any of various other durable and generally resilient materials.
The rear side of the receptacle housing 70 (as shown in FIGS. 3 and 5) is a substantially flat surface configured to comfort to the contours of the wearer's chest, since this rear side faces the body of the wearer. This rear side of the receptacle housing 70 is also bonded to the fabric portions 12 of the garment 10, and particularly the outer surface of the fabric. This bonding may be accomplished using any of various means as will be recognized by those of ordinary skill in the art, including the use of adhesives, heat welding, stitching, or any of various other means. Because the rear side of the receptacle housing 70 is attached to the fabric of the garment 10, the opposing front side of the receptacle housing 70 faces away from the body of the wearer and is exposed on the outside of the garment 10. The front side of the receptacle housing 70 (as shown in FIG. 6) is more contoured than the rear side and configured to receive and retain the electronics module 22, as explained in further detail below.
With particular reference to FIG. 5, when the electrode lead 50 is positioned in the receptacle housing 70, the rear plate 52 of the electrode lead 50 is exposed on the rear of the receptacle housing 70. The finger 64 extends through a channel 72 in the receptacle housing 70 that curves and generally follows the same contour of the finger 64. The channel 72 does not bore through the receptacle housing 70, but is instead oriented substantially parallel to the generally flat rear surface of the receptacle housing 70. In other words, the channel 72 is elongated in a direction that extends substantially parallel to the rear surface of the receptacle housing 70. The tangs 54 are positioned on the opposite side of the rear plate 52 and are crimped to the electrode 16 in order to attach the electrode 16 to the electrode lead 50, as described above.
The channel 72 in the receptacle housing 70 leads to a cavity 74. One end of a connection pin 80 is positioned in the cavity 74. The connection pin 80 is fixed in place within the receptacle housing 70 and includes a first end 82 and a second end 84 (not shown in FIG. 5). The first end 82 of the connection pin 80 includes a domed surface that extends into the cavity 74. The finger 64 of the leaf spring 60 engages the domed surface on the connection pin 80 within the cavity 74 by abutment but is not attached to the connection pin. The surface of the finger 64 that engages the connection pin 80 is relatively smooth. The combination of the domed surface of the connection pin 80 and the smooth surface of the finger 64 allows the finger to be easily inserted into the cavity 74 and establish a good electrical connection via the abutment between the electrode lead 50 and the connection pin 80. In at least one embodiment, a bumper 76 is positioned in the channel 72. The bumper 76 is integrally formed with the receptacle housing 70 and further helps in directing the finger 64 into proper engagement with the connection pin 80 during assembly of the receptacle 20. Additionally, the bumper 76 helps maintain proper abutment of the finger 64 and the connection pin 80 following repeated vibrations and impacts to the receptacle during use.
Receptacle for Electronics Module
FIG. 6 shows the front side of the receptacle housing 70 (i.e., the reverse side from that shown in FIG. 3). As shown in FIG. 6, the front side of the receptacle housing 70 includes a contoured base 90 with a central perimeter 92. A socket 94 is defined on the front surface of the receptacle housing 70 within the contoured base 90. An entrance to the socket 94 is defined by the central perimeter 92 of the contoured base 90. The central perimeter 92 defines a lip on the receptacle housing 70 with the recess provided by the socket 94 extending behind the lip (i.e., under the lip when the receptacle 20 is viewed from a top position). The socket 94 is further defined by a circular sidewall 96 and a back wall 97 of the socket 94. While the circular sidewall 96 may be formed in a perfectly circular shape, it will be recognized that the term “circular” as used herein simply refers to a curved or annular shape that is substantially circuitous. A recess 99 is formed on an upper portion of the circular sidewall 96. This recess 99 is configured to receive a tab on the electronics module, as explained in further detail below. Also, a detent 98 is positioned in the socket 94, extending forwardly from the back wall 97. The detent 98 is configured to engage features on the electronics module 22, as explained in further detail below.
The receptacle 20 is configured to receive and retain the electronics module 22 within the socket 94 and also facilitate electrical connection between the electronics module 22 and the electrodes 16 of the sensor arrangement 14. Accordingly, the connection pin 80 that engages the electrode leads 50 within the contoured base 90 also extends into the socket 94. In particular, a second end 84 of each connection pin 80 extends into the socket 94 through an opening in either the sidewall 96 or the back wall 97 of the socket 94. In the embodiment of FIG. 6, the second end 84 of the connection pin 80 is provided on the back wall 97 and at the base of the sidewall 96. Advantageously, this orientation and arrangement of the connection pin 80 allows contacts on the electronics module 22 to make electrical connection with the receptacle 20 without posts or other electrical contact members extending directly into the back wall 97 of the socket and toward the wearer (i.e., the electrical contact members are not perpendicular to the back wall 97 and the chest of the wearer). This provides an added safety feature for the sensor arrangement 14 disclosed herein. Instead of an orientation with an elongated electrical contact being perpendicular to the wearer (and the back wall 97 of the socket 94), the connection pin 80 disclosed herein is substantially parallel to the back wall 97 of the socket 94. Moreover, insertion and removal of the electronics module 22 from the receptacle 20 is made easier in the disclosed embodiment by the design of the electrical contacts near or in the sidewall 96 of the socket 94.
In the disclosed embodiment, the second end 84 of the connection pin 80 that extends into the socket is substantially smooth and flat with a relatively large surface area to facilitate engagement with a contact on the electronics module 22. However, it will be appreciated that in other embodiments the ends of the connection pin 80 may be any of various shapes. Moreover, it will be recognized to those of ordinary skill in the art that the connection pin 80 may be replaced with any other adequate electrical conductor, and need not be provided in the shape of a pin or other post-like member.
The electrode leads 50 may be positioned within the receptacle housing 70 using any of various methods. For example, the electrode leads 50 may be insert molded, press-fit or otherwise molded or inserted into the receptacle housing during manufacture of the receptacle 20. In at least one embodiment, the electrode leads are inserted into the receptacle housing by threading the finger 64 through the associated channel 72 of the receptacle housing 70, past the bumper 76 and into an interference fit with the connection pin 80 in the cavity 74 of the receptacle housing. Thereafter, or before insertion of the finger 64 through the channel 72, the tangs 54 are inserted through the holes 46 in the electrodes 16 and crimped around the electrode material.
Electronics Module
With reference now to FIGS. 7-9, the electronics module 22 is shown. The electronics module 22 includes a microprocessor 102, power device in the form of a power cell 104, and electronic transceiver 106 all contained within a module housing 100. The module housing 100 is generally disc shaped and includes a rounded front face 110, a substantially flat rear face 112, and a circular sidewall 114 with a medial groove 116. The rear face 112 is configured for insertion into the socket 94 in the receptacle housing 70. The medial groove 116 is defined between an outer rim 118 and an inner rim 120 on the circular sidewall 114. The medial groove 116 is adapted to receive the central perimeter 92 of the receptacle housing 70 when the rear face 112 of the electronic module 22 is inserted into the socket 94. In other words, the central perimeter 92 of the receptacle housing 70 is positioned between the outer rim 118 and the inner rim 120 of the medial groove 116 when the electronics module 22 is seated in the receptacle 20. As a result, the front face 110 and the outer rim 118 of the electronics module 22 are positioned outside of the socket 94, but the rear face 112 and the inner rim 120 are positioned inside of the socket 94 when the electronics module 22 is seated in the receptacle 20.
With continued reference to FIGS. 7-9, the inner rim 120 of the module housing 100 further includes two contacts 130 that provide an electrical connection to the microprocessor 102 inside the electronics module 22. Each contact 130 is provided as a small pin that extends outward from the inner rim 120 of the circular sidewall 114 on the electronics module 22 and is retained by the module housing 100. The contacts 130 may be spring biased or fixed in place on the circular sidewall. Each contact 130 has a dome shaped end portion that is configured to engage the relatively flat second end 84 of the connection pin 80 in the receptacle 20. As discussed previously, the contacts 130 may be oriented to extend outward from the circular sidewall 114 because of the arrangement of the electrical conductors in the receptacle 20 including the electrode leads 50 and the connection pins 80 that facilitate a sidewall electrical connection to the electronics module 22. Electric signals from the electrodes 16 are directed through the electrical leads 50 and to the connection pin 80. The connection pin 80 provides an electrical connection to the microprocessor 102 where the electric signals are then processed. Electric signals processed by the microprocessor may then be transmitted by the transceiver 106 to a remote device for further processing. The electronics module 22 may also be referred to as a “sensor module”, as the electronics module 22 receives biometric signals derived from a wearer.
An orientation recess 140 is also provided on the inner rim 120 of the circular sidewall 114 on the electronics module 22. The orientation recess 140 is configured to engage the detent 98 in the socket 94 of the receptacle housing 70 and properly orient the electronics module 22 when it is inserted into the receptacle 20. In particular, when the detent 98 is received within the orientation recess 140, the contacts 130 on the electronics module 22 are properly aligned with the connection pin 80 in the socket 94 of the receptacle 20, and an electronic connection is established between the electronics module 22 and the receptacle 20 and associated electrodes 16.
The outer rim 118 of the electronics module 22 further includes an upper tab 122 designed to facilitate easy removal of the electronics module 22 from the receptacle 20. Because the outer rim 118 is positioned above the central perimeter 92 of the receptacle housing 70, and because the upper tab 122 fits into the recess 99 of the receptacle 20, the user may easily engage the rear of the upper tab 122 with his or her finger and force the upper tab 122 away from the receptacle 20. When sufficient force is applied, the medial groove 116 of the module housing 100 is released from the central perimeter 92 of the receptacle housing 70 and the electronics module 22 is dislodged from its seat in the receptacle 20.
Electronics Module with Dual Injection Material Housing
With reference now to FIGS. 10A-10D, in at least one embodiment, the electronics module 22 includes a multi-component injection molded module housing 200. The electronics module 22 of FIGS. 10A-10D generally includes the same parts as described above with respect to FIGS. 7-9. However, the module housing 200 in the embodiment of FIGS. 10A-10D is comprised of two different materials that provide advantageous features for the module housing 200. In particular, the module housing 200 includes first portions 220 made of a first material comprised of a relatively soft and resilient polymer material such as thermoplastic polyurethane (TPU), and second portions 230 made of a second material comprised of a relatively hard and rigid polymer material such as polycarbonate.
With particular reference to FIG. 10A, the module housing 200 includes a front face 210 with a perimeter portion 222, a circular interior portion 224, a circular intermediate portion 232, and a logo portion 234. The perimeter portion 222 and the circular interior portion 224 are both comprised of the first material. The circular intermediate portion 232 and the logo portion 234 are both comprised of the second material. Because the perimeter portion 222 and the circular interior portion 224 make up most of the front face 210, the front face 210 has an overall compliant feel with most of the front face comprised of the soft and resilient material. A tab 226 is included on the upper portion of the front face 210. This tab 226 may be easily grasped by a user, or the user may place a finger behind the tab 226, in order to urge the module 200 out of the receptacle.
With particular reference to FIG. 10B, the module housing 200 also includes a rear face 212 that is completely or predominantly comprised of the second material, such that the rear face 212 is relatively hard and rigid. FIGS. 10C and 10D show that the perimeter portion 222 of the front face 210 extends down the sidewall 240 toward the rear face 212, and the rear face 212 extends upward on the sidewall 240 toward the front face 210. The two portions meet along a ridge 242 in the sidewall. In at least one location on the module, the second material extends through a hole in the first material, such as the tab 244 shown in FIG. 10C. The tab 244 is comprised of the second material and extends through an opening in the first material to assist in locking the first portions 220 to the second portions 230. The front face 210 and the rear face 212 of the module housing 200 may be formed as a single component or two different components using a multi-shot injection molding process wherein the first portions 220 and second portions 230 are formed during the same molding process. Because the rear face 212 of the module housing 200 is predominantly comprised of the relatively hard and rigid second material, a strong backbone is provided for the electronics module 22. At the same time, because the front face 210 is mostly comprised of the relatively soft and resilient first material, the electronics module 22 has a soft and supple feel in the hand of a user. Furthermore, the front face provides shock absorption qualities to the electronics module 22 if it is dropped. Further still, the first and second materials may be comprised of different colored polymers, allowing a unique design to be provided by the module housing 200 that does not easily wear away over time.
In at least one embodiment, the first material of the module housing is substantially opaque while the second material of the module housing 200 is a translucent material. In this embodiment, the electronics module 22 includes a plurality of lights positioned behind the second portions 230 of the front face 210. For example, with reference to FIG. 9, the plurality of lights may be LEDs 250 mounted adjacent to the microprocessor 102 and power cell 104 on the front face side of the module 22. Because the LEDs 250 are positioned behind the translucent second portions 230 of the front face, the LEDs may be used to provide visual signals to a user of the electronics module. The LEDs 250 may include a first LED 252 of a first color, a second LED 254 of a second color, and a third LED 256 of a third color. Each LED may be used to indicate a different status or functional operation of the electronics module 22. For example, the first LED 252 may indicate that the electronics module 22 is powered on. The second LED 254 may indicate that the electronics module 22 is communicating with a remote device via the transceiver 106. The third LED may indicate a particular mode for the electronics module, such as a “team mode” wherein special data collection or data transmission activity occurs that processed and used within a group or team application in contrast to an individual application. While the translucent second portions 230 allows light from the LEDs to be seen through the second material, the substantially opaque first portions provide ultra-violate and visible light protection to the electronic components within the electronics module.
Receptacle with Dual Injection Material
With reference now to FIG. 11, in at least one embodiment, the receptacle 20 on the garment 10 is a multi-component injection molded receptacle. The receptacle 20 of FIG. 11 generally includes the same parts as described above with respect to FIGS. 3-6. However, the receptacle 20 in the embodiment of FIG. 11 is comprised of two different materials that provide advantageous features for the receptacle 20. In particular, the receptacle 20 includes first portions 260 made of a first material comprised of a relatively soft and resilient polymer material such as thermoplastic polyurethane (TPU), and second portions 270 made of a second material comprised of a relatively hard and rigid polymer material such as polycarbonate.
The multi-component injection molded receptacle 20 of FIG. 11 includes a socket 280 with a circular sidewall 282 and a back wall 284. An upper portion 262 of the socket 280, including upper portions of the sidewall 282 and the back wall 284, is comprised of a relatively soft and resilient polymer material, such as TPU. A lower portion 272 of the back wall, including lower portions of the sidewall 282 and the back wall 284, is comprised of a relatively hard and rigid polymer material, such as polycarbonate. As shown in FIG. 11 a joint 286 may be seen between the upper portion 262 and the lower portion 272 of the socket 280. The joint 286 is provided in the shape of a square wave, and provides a boundary between the upper portion 262 and the lower portion 272 of the socket 280. In other embodiments, the joint 286 may be differently shaped or may only extend along the back wall 284 of the socket 280 such that the entire circular sidewall of the receptacle is comprised of the second material, and only the back wall 284 is comprised of the first material.
The relatively soft and resilient upper portion 262 of the socket 280 is configured to flex substantially more than the relatively hard and rigid lower portion 272 of the socket 280 when a flex force from a human hand is applied to the receptacle 20. This allows the wearer to more easily dislodge the electronics module 22 from the receptacle 20. In particular, a when a wearer of the garment 10 wishes to remove the electronics module 22 from the receptacle 20, the wearer may flex the upper part of the receptacle 20 away from the electronics module 22, thus providing access to the rear of the upper tab 122 on the electronics module 22. The user may then use his or her finger to force the upper tab 122 of the electronics module 22 away from the socket 280 and dispel the electronics module 22 from the socket 280. Alternatively, when a user wishes to remove the electronics module 22 from the receptacle 20, the user may simply press against the rear of the upper part 262 of the socket 280, thus forcing the resilient upper part 262 of the socket 280 against the rear face 212 of the electronics module 22 and unseating the electronics module 22 within the receptacle 20.
While the upper portion 262 of the socket 280 is configured to facilitate removal of the electronics module 22 from the socket 280, the lower portion 272 of the socket 280 is configured to facilitate retention of the electronics module 22 in the socket 280. In particular, because the lower portion 272 is comprised of a relatively hard and rigid material, such as polycarbonate, the lower portion 272 protects the electronics module 22 within the socket 280 and prevents the electronics module 22 from easily falling out of the socket 280. Accordingly, a force applied to the lower portion 272 of the socket 280 will not easily remove the electronics module 22 from the socket 280.
One-Piece Fabric Strap
With reference now to FIGS. 12A-12C, in at least one embodiment, the garment 10 is provided in the form of a torso strap 300. The torso strap 300 is comprised of a unitary but elongated sheet of fabric 302 that extends from a first end 304 to a second end 306 of the torso strap. A first loop 310 is formed at the first end 304 of the strap 300. A buckle 314 is provided on the strap near the second end 306 and is configured to adjust the length of the strap 300. A second loop 312 is formed between the second end 306 and the buckle 314. A clip 316 is attached to the second end 306 and engages the second loop 312. The clip 316 may be comprised of a relatively hard and rigid material, such as metal or a hard polymer. The clip 316 includes an arm configured to extend into the first loop 310, thus coupling the first end 304 of the strap 300 to the second end 306. The single arm on the clip 316 may be easily inserted into the loop 310, providing a quick connection arrangement between the first end 304 and the second end 306 of the strap 300.
The sheet of fabric 302 that forms the strap is comprised of a woven or knit fabric material. In at least one embodiment, the fabric 302 is a spandex material or other material comprised of elastane fibers. Advantageously, the sheet of fabric 302 extends from the first end 304 to the second end 306 of the strap 300. As a result, only a single small clip is needed to connect the first end 304 of the strap to the second end 306 of the strap. There is no need for multiple clips and multiple clip locations as is typical with conventional straps.
The receptacle 20 is mounted on a portion of the strap 300 that is located near a center of the torso of the wearer. The sheet of fabric 302 surrounds the receptacle 20 on the front of the strap 300, extending to the right and left as well as upward and downward from the receptacle. As a result, the wearer is provided with a strap 300 that is generally uniform from the first end to the second end, as the sheet of fabric 302 extends from the first end 304 to the second end 306 and is only interrupted by the clip 316 in a circle around the torso of the wearer. As shown in FIG. 12C, the electrodes 16 (noted by dotted lines) are exposed on the rear of the strap 300. The sheet of fabric 302 also extends from the first end 304 to the second end 306 of the strap 300 on the rear of the strap, covering all of the rear of the strap except the electrodes, including portions on the rear of the strap that are directly behind the receptacle 20. This adds greater comfort to the wearer. It will be noted that the sheet of fabric provided on the rear of the strap 300 may be the reverse side as the sheet of fabric on the front of the strap. Alternatively, the sheet of fabric provided on the rear of the strap 300 may be a supplemental sheet to that on the front of the strap 300.
The foregoing detailed description of one or more embodiments of the garment with receptacle and electronics module has been presented herein by way of example only and not limitation. It will be recognized that there are advantages to certain individual features and functions described herein that may be obtained without incorporating other features and functions described herein. Moreover, it will be recognized that various alternatives, modifications, variations, or improvements of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be desirably combined into many other different embodiments, systems or applications. For example, various alternative materials may be used in different embodiments of the invention. Additionally, while the receptacle and electronics module have been described herein with respect to a heart rate monitor, it will be appreciated that the arrangement could be used with any different number of sensor arrangements that include or do not include a heart rate monitor. Presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the appended claims. Therefore, the spirit and scope of any appended claims should not be limited to the description of the embodiments contained herein.

## Claims

1. A sensor arrangement comprising:
a garment;
at least one electrode positioned on the garment;
a multi-component injection molded receptacle provided on the garment, the multi-component injection molded receptacle including a socket with a back wall, a first part of the back wall comprised of a relatively soft and resilient polymer material and a second part of the back wall comprised of a relatively hard and rigid polymer material, the relatively soft and resilient polymer material configured to flex substantially more than the relatively hard and rigid polymer material when a flex force from a human hand is applied to the receptacle, the receptacle further including an electrode lead electrically connected between the at least one electrode and the socket; and
a sensor module configured to be removably inserted into the socket of the receptacle and contact the electrode lead, the sensor module including a multi-component injection molded housing including a front face, the front face including a first portion and a second portion, the first portion comprised of the relatively soft and resilient polymer material and the second portion comprised of the relatively hard and rigid polymer material.

2. The sensor arrangement of claim 1 wherein the relatively soft and resilient polymer material is thermoplastic polyurethane.

3. The sensor arrangement of claim 2 wherein the relatively hard and rigid polymer material is polycarbonate.

4. The sensor arrangement of claim 3, the relatively hard and rigid polymer material provided as a logo on the front face of the sensor module.

5. The sensor arrangement of claim 3 wherein the polycarbonate is translucent and a plurality of lights are positioned behind the polycarbonate.

6. The sensor arrangement of claim 5 wherein the plurality of lights include a first color light, a second color light and a third color light.

7. The sensor arrangement of claim 6 wherein the first color light indicates that the sensor module is powered on, the second color light indicates that the sensor module is communicating with a remote device, and the third color light indicates a mode for the sensor module.

8. The sensor arrangement of claim 1 wherein the first portion provides most of the front face.

9. The sensor arrangement of claim 8, the sensor module further comprising a rear face positioned behind the front face, the rear face also comprised of the relatively hard and rigid material.

10. The sensor arrangement of claim 1, the receptacle further comprising at least one receptacle contact exposed to the socket and engaging the electrode lead, the receptacle contact further engaging a module contact when the sensor module is positioned in the socket.

11. The sensor arrangement of claim 10 wherein the at least one receptacle contact is a connection pin that is elongated in a direction that extends substantially parallel to the back wall of the receptacle.

12. The sensor arrangement of claim 11 wherein the sensor module includes a circular sidewall and the module contact extends outward from the circular sidewall in a direction substantially parallel to the back wall of the receptacle when the sensor module is positioned in the socket.

13. The sensor arrangement of claim 10, the at least one electrode lead including an elongated curved finger that extends through a channel in a sidewall of the receptacle.

14. The sensor arrangement of claim 13 wherein the finger is a curved finger with a substantially smooth surface that engages a domed end of the receptacle contact in a cavity of the receptacle.

15. The sensor arrangement of claim 14 further comprising a bumper positioned in the channel, the bumper configured to urge the curved finger into engagement with the domed end of the receptacle contact.

16. The sensor arrangement of claim 1 wherein a socket entrance is defined by a circular lip along a rim of the socket, and wherein the sensor module includes a circular groove formed in a circular sidewall, the circular lip of the receptacle engaging the circular groove when the sensor module is positioned within the socket.

17. The sensor arrangement of claim 1 wherein the garment is a torso strap, the torso strap comprising fabric extending from a first end to a second end of the torso strap with a relatively rigid clip configured to couple the first end to the second end of the torso strap.

18. A garment configured to be worn on a torso of a wearer, the garment comprising:
a fabric portion configured to engage the torso of the wearer;
an electrode fixedly connected to the fabric portion, the electrode configured to engage the torso of the wearer;
a receptacle fixedly connected to the fabric portion, the receptacle comprising:
a receptacle housing providing a socket, the receptacle housing including an upper portion comprised of a relatively soft and resilient polymer material and a lower portion comprised of a relatively hard and rigid polymer material, the relatively soft and resilient polymer material configured to flex substantially more than the relatively hard and rigid polymer material when a flex force from the wearer is applied to the receptacle; and
an electrode lead provided within the receptacle, the electrode lead providing an electrical connection between the electrode and the socket; and

an electronics module releasably positioned in the socket, the electronics module including a module housing with a module contact retained by the module housing, the electronics module further comprising a processor, a power device, and a transmitter positioned within the module housing, wherein the module contact is electrically connected to the electrode lead when the electronics module is positioned in the socket.

19. The garment of claim 18, wherein the relatively soft and resilient polymer material is thermoplastic polyurethane and the relatively hard and rigid polymer material is polycarbonate.

20. A garment configured to be worn on a torso of a wearer, the garment comprising:
a fabric portion configured to engage the torso of the wearer;
an electrode fixedly connected to the fabric portion, the electrode configured to engage the torso of the wearer;
a receptacle fixedly connected to the fabric portion, the receptacle comprising a receptacle housing, a socket defined by the receptacle housing, and an electrode lead, the electrode lead extending through the receptacle housing and providing an electrical connection between the electrode and the socket; and
an electronics module configured to be removably inserted into the socket of the receptacle and contact the electrode lead, the electronics module including a multi-component injection molded housing including a front face, the front face including a first portion and a second portion, the first portion comprised of a relatively soft and resilient polymer material and the second portion comprised of a relatively hard and rigid polymer material.