Patent ID: 12237632

DETAILED DESCRIPTION

In the following detailed description of the invention of exemplary embodiments of the invention, reference is made to the accompanying drawings (where like numbers represent like elements), which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, but other embodiments may be utilized and logical, mechanical, electrical, and other changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

In the following description, specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known structures and techniques known to one of ordinary skill in the art have not been shown in detail in order not to obscure the invention. Referring to the figures, it is possible to see the various major elements constituting the apparatus of the present invention.

Referring toFIG.1, shown is an expanded (or exploded) view of an overall assembly10of a controller device12(e.g. electronic module) electrically connected to conductive pathways80(seeFIG.16) of a textile substrate34(e.g. in the form of a patch, band, shirt, pants, socks, undergarment, blanket, hat, glove, shoe, etc.) by way of a module dock station14. As such, the module dock station14(seeFIG.5) can comprise a dock housing50having a body14awith an aperture52for providing access between an electrical dock connector54(seeFIG.4) coupled to the conductive pathways80and an electrical controller connector26(seeFIG.1) that is connected to electronics22of the controller device12, as further described below. The module dock station14can also have one or more clips55(as an example of a releasably securable mechanism for mechanically coupling with the housing18,24of the controller device12). It is clear that the mating electrical connection between the electrical dock connector54and the electrical controller connector26is also releasably securable, thus facilitating repeated installation and removal of the controller device12with respect to the module dock station14, both mechanically as well as electrically.

Periodic removal of the controller device12could be advantageous for recharging of a power source70(seeFIG.1) of the controller device12, replacement/substitution of the controller device12(including the electronics22), and/or temporary removal of the controller device12for washing/cleaning purposes of the textile substrate34(e.g. when washing a garment which integrally incorporates the textile substrate34as part of the overall garment construction).

Referring again toFIG.1, the controller device12has a housing18,24(e.g. a top enclosure and a bottom enclosure) providing a moisture resistant housing for the enclosed electronics22. For example, referring toFIG.6, the electronics22can include a power source70(e.g. rechargeable battery) powering a memory72and a computer processor74, such that the computer processor executes instructions store on the memory (e.g. ROM, RAM, etc.). The electrical connections between the electronics22can be by way of conductive pathways76(shown in concept) on a printed circuit board (PCB) or other electronics substrate78. The conductive pathways76can be electrically connected to the electrical controller connector26(e.g. a socket connector—e.g. an 8 socket connector), such that the electrical controller connector26can be considered as integral within the housing18,24(seeFIG.7). As such, the electrical controller connector26can be considered as part of the controller device12.

The bottom enclosure24of the housing can include apertures79afor receiving corresponding pins79bmounted on a body54aof the electrical dock connector54(e.g. an 8 pin connector). It is also envisioned that the electrical dock connector54can be a socket connector and the electrical controller connector26can be a pin connector26configured for mating with the socket connector54. It is also recognized that the electrical connectors26,54can have mating electrical connections other than of the pin/socket type (e.g. magnetic), as desired, in so much that the electrical connectors26,54are of the releasably securable type. As shown inFIG.8, the electrical controller connector26can be sealed via a seal82(e.g. adhesive) with respect to an interior surface84(of the housing18,24when assembled). The seal82can be used to inhibit moisture or other foreign matter from entering into the interior86(seeFIG.7) via the apertures79a(seeFIG.7).

Referring again toFIG.1, the overall assembly10also includes a first substrate28and a second substrate30for mounting on either side of the textile substrate34. For example, the first substrate28can be a PCB. As shown inFIG.2, the first substrate28has the electrical dock connector54mounted thereon, with conductive pathways43connecting each of the one or more electrical connectors79b(e.g. pins, sockets, etc.) of the electrical dock connector54with corresponding one or more electrical connection locations42mounted on the first substrate28. It is recognized that the one or more electrical connection locations42can be distributed about a surface28aof the first substrate28, such that each of the locations of the one or more electrical connection locations42correspond (e.g. in relative distance from one another) with the conductive pathways80(seeFIG.16) laid out on/in the textile substrate34. The first substrate28can also have one or more electrical components25mounted thereon and thus electrically connected to the electronics22via the mated connectors26,54(pins/sockets) via corresponding conductive pathway(s)43. As shown, the first substrate28can have a plurality of apertures28bcorresponding in spatial distribution with the spatial distribution of holes34bof the textile substrate34(seeFIG.4). The apertures28bare also matching in spatial distribution with a series of apertures30bof a surface30aof the second substrate30(e.g. a PCB). In assembly of the overall assembly10, the first substrate28can be mounted on a corresponding surface34aof the textile substrate34by an adhesive layer A. In assembly of the overall assembly10, the second substrate30can be mounted on a corresponding opposing surface34aof the textile substrate34by a similar adhesive layer A.

Referring toFIG.3, the second substrate30is mounted on an opposite surface34aof the textile substrate34to that used to mount the first substrate28, such that the textile substrate34is securely fastened between the substrates28,30, as further described below. The second substrate30also has connection locations42acorresponding to the electrical connection locations42, such that corresponding mechanical fasteners29(e.g. rivets—seeFIG.2) can be used to mechanically fasten the first substrate28to the second substrate30, thus fixedly sandwiching/mounting the textile substrate34there-between).

Referring again toFIG.4, an optional pocket35of the textile substrate34can be used to house the first substrate28, as desired. As can be seen inFIG.5, the optional pocket35can also be used to house the module dock station14, when fastened to the first substrate28(further described below). Referring again toFIG.1, the second substrate30can be covered by an optional backing32(e.g. fabric, plastic, padding, laminate, etc.) material, so as to provide for comfort of the wearer of the textile substrate34(e.g. as incorporated into a garment), when the backing32material is in contact with a skin of the wearer. The overall assembly10can also include a light pipe16(for indicating functional status of the electronics22via one or more visual indicators (e.g. LEDs) as well as a positioned magnet20in the interior86of the housing18,24. In summary, the housing18,24of the controller device12, once assembled, can be releasably secured, both mechanically and electrically, with the module dock station14. The module dock station14is fixedly attached to the first substrate28, which is in term fixedly attached to the textile substrate34via the mechanical (e.g. fasteners)/chemical (e.g. adhesive) connection between the first substrate28and the second substrate30when positioned on opposed sides34aof the textile substrate34.

Referring again toFIGS.2,3,4, the apertures28b,30band holes34bcan be used to fasten the module docking station14with the substrate(s)28,30to one another, thus fixedly securing the module docking station14to the textile substrate34. For example, one fastening method of the module docking station14with the substrate(s)28,30can be using a staking method (seeFIGS.5,9,15), whereby staking is the process of connecting the two components (the module docking station14with the substrate(s)28,30) by creating an interference fit of a fastener90between the two pieces (the module docking station14with the substrate(s)28,30). One workpiece28,30has a hole28b,30bin it while the other (the module docking station14) has a boss90that fits within the hole28b,30b. It is recognized that one of the workpieces28,30can have the respective hole(s)28b,30bwhile the other of the pieces (the module docking station14) can have the fastener(s)90mounted on the corresponding surface28a,30a. The fastener90(e.g. boss) can be very slightly undersized so that it forms a slip fit with the hole28b,30b. A staking punch can then be used to expand the boss90radially and to compress the boss90axially so as to form an interference fit between the workpieces (the module docking station14with the substrate(s)28,30). This interference fit forms a permanent join(s)/connection(s) between the two pieces, such that the interposed textile substrate34is fixedly secured between the two substrates28,30which in turn is fastened to the module docking station14via the staking. The staking process can also be referred to as thermoplastic staking, also known as heat staking, which is the same process except that it uses heat to deform the plastic boss90, instead of cold forming. A plastic stud90protruding from one component fits into a hole in the second component. The stud90is then deformed through the softening of the plastic to form a head which mechanically locks the two components (the module docking station14with the substrate(s)28,30) together. Unlike welding techniques, staking has the capacity to join plastics to other materials (e.g. metal, PCB's) in addition to joining like or dissimilar plastics, and it has the advantage over other mechanical joining methods in reducing the need for consumables such as rivets and screws.

Referring toFIGS.10and11, shown is an example backing32in order to cover the second substrate30after being fastened to the first substrate28. Referring toFIGS.12,13,14, shown is the housing18,24in an unassembled and assembled form, such that the interior86with mounted light pipe16and magnet20are shown by example. Referring toFIG.16, shown is a cross sectional view of the overall assembly10, including an optional piezo sensor mounted between the first substrate28and the body14aof the module dock station14.

Referring toFIG.16, shown is an example textile substrate34with the conductive pathways80, as an illustration only, with the locations of the electrical connector locations42(and/or fasteners29) ofFIG.2in ghosted view. It is recognized that an electrical connection between the electrical connector locations42and the conductive pathways80is fixed when the electrical connector locations42(of the first substrate28) come into contact with the conductive pathways80, which is maintained due to 1) the fixed connection (e.g. via fasteners90) between the substrates28,30thus sandwiching the textile substrate34there between and biasing the electrical connectors locations42and the conductive pathways80into physical contact with one another; and/or 2) the connection via the fasteners29(e.g. conductive fasteners such as metal rivets, pins, etc.) between the substrates28,30as the fasteners29are in physical contact with the electrical pathways80as well as the electrical connector locations42. The substrates28,30can be made of flexible or rigid material, as desired, so long as the material retains the interconnection between the locations42by the fasteners29.

For example, electrical current to the electronics22follows the electrically conductive path of: a) from the conductive pathways76to b) the electrical controller connector26to c) the electrical dock connector54to d) the conductive pathways43connecting each of the one or more electrical connectors79b(e.g. pins, sockets, etc.) of the electrical dock connector54to e) corresponding one or more electrical connection locations42to finally f) (e.g. via the fasteners29) positioned adjacent to and electrically bonded to the conductive pathways80of the textile substrate34. Similarly, electrical current from the conductive pathways80of the textile substrate34follows the electrically conductive path of: a) (e.g. via the fasteners29) positioned adjacent to and electrically bonded to the conductive pathways80of the textile substrate34to b) corresponding one or more electrical connection locations42to c) the conductive pathways43connecting each of the one or more electrical connectors79b(e.g. pins, sockets, etc.) of the electrical dock connector54to d) the electrical dock connector54to e) the electrical controller connector26to f) the conductive pathways76connected to the electronics22.

In fabrication of the overall assembly10, the following example manufacturing processes can be performed.FIG.17shows an example process102for manufacture of the textile substrate34including the conductive pathways80(e.g. circuits containing conductive wires/fibres with attached sensors/actuators applied on or otherwise interlaced, knit/woven, with the fibres of the textile substrate34).FIG.18shows an example method steps104to manufacture the sandwich of the two substrates28,30with the textile substrate34. Referring toFIG.19, shown is a method106to fasten (e.g. mechanical) the module docking station14to the first substrate28underlying and adjacent to the module docking station14. Further, the backing32is fastened (e.g. adhesive) to the second substrate30underlying and adjacent to the backing32.FIG.20is an example manufacture108of the electrical controller connector26onto the housing18,24of the controller device12.FIG.21is a method of manufacture110for the main controller device12, including mounting of the components16,20,22within the interior86of the housing18,24and sealing the housing18,24.

As shown above by example, the overall assembly10included the controller device12, the module dock station14fixedly connected to the substrate(s)28,30, and the substrates28,30fixedly connected to the textile substrate34(having the plurality of conductive pathways80). As such, the controller device12, once assembled, is both mechanically and electrically releasably securable to the module dock station14, in order to effect electrical communication between the electronics22of the controller device12and the conductive pathways80of the textile substrate34.

Accordingly, described by example only is: (a) light pipe16, (b) top enclosure18, (b) magnet20, (c) main electronics22which can contain (d) the main PCB28, (e) battery70and (f) other electronic components72,74,76, (g) bottom enclosure24, which holds (h) the connector PCB26, (i) module dock14, (j) top textile PCB28which are located above the (j) textile band34and under the (k) textile pocket35and the (l) bottom textile PCB30and (m) fabric and laminate padding32, which are located below the textile band34.

Further, the embodiments comprise apparatus and methods to make a reliable interconnection between electronic devices12and smart textiles34. The embodiments facilitate the electronic device12to maintain a robust electrical connection to electrically conductive circuits80on the smart textile34while also being securely mechanically fastened to the smart textile34, thus acquiring the ability to withstand mechanical shock, torsion, stretch and other stresses to which the smart textile34or electronic devices12may be subject to.

In some embodiments the textile band34or textile substrate34may contain no electrical or electronic components. In some embodiments, the textile substrate34may contain only electrically conductive circuits80, such as electrically conductive yarn, fiber or printed electronic circuits. In other embodiments, the textile substrate34may contain fully functional and active electronic components, sensors, circuits and the like.

For the purposes of a wearable smart textile34worn on the body, the direction of below the textile band34would be interpreted as being closer to the body and above the textile band34would be farther away from the body. The textile pocket35is preferably a structure which is raised above the textile band34and fabricated by knitting into the textile band34knit structure.

In some embodiments, the textile substrate34(also called the textile band34) has successfully incorporated health monitoring sensors in the form of ECG sensor pads, respiratory monitoring sensors and bio-impedance monitoring sensors. These sensors are electrically connected to conductive circuits80within the textile band34, which are then connected using rivets29, eyelet or grommets42leading to the hard electronics22(e.g. mounted on the PCB78). In other embodiments, the main electronics PCB78has also successfully incorporated motion sensors and temperature sensors onto the module PCB78, as part of the electronics22.

FIG.17illustrates embodiment comprising textile form factors to which the textile substrate34has been successfully applied, including: underwear, bra and shirts. It can be appreciated that the embodiments are applicable to any form of textile substrate34or flexible substrate34exhibiting similar properties to a textile or fabric.

FIG.18illustrates the steps relating to assembling the top textile PCB28onto the textile band34with this embodiment comprising steps, including: (1) Placing an adhesive material A on the bottom side of the top textile PCB28, (2) Inserting the top textile PCB28inside the textile pocket35by aligning the holes42on the top textile PCB28to the matching pre-punched rivet holes34bonto the textile band34, (3) Placing double-sided adhesive A on the bottom textile PCB30and placing it on the opposite side34aof the textile band34to the top textile PCB28, also aligning to the pre-punched rivet holes34bin the textile band34, and (4) Pressing the rivets29at the same time as applying even pressure to the PCBs28,30.

Steps 1-4, above, create a robust and secure mechanical and electrical connection between the top textile PCB28, the bottom textile PCB30and the textile band34. In regions where an electrical connection is required, the pre-punched rivet holes34bin the textile band34can be located such that an electrical conductive circuit80in the textile band34is physically in contact with the metal rivet29an/or the conductive locations42(e.g. part of the conductive pathways43positioned on the underside of the first substrate28(and thus able to be placed into direct contact with the surface34aof the textile substrate34). It should be noted that rivet29can also mean eyelet, grommet or similar type of metal fastening method.

The textile band pocket35, which is fabricated in such a manner as to be raised above the surface34aof the textile band34facilitating just enough room for the module dock housing50to fit snugly within the pocket35, while also facilitating it to be removed when necessary.

FIG.19illustrates the steps106relating to assembling the module dock14and dock backing32into the textile band34, with this embodiment comprising steps, including: (1) Applying epoxy to the dock14and placing it inside the pocket35by aligning the heat stacking poles90to the holes28b,30bon the textile PCBs28,30, (2) Heat staking the dock14onto the textile PCB28,30,34assembly, (3) Applying epoxy to the dock backing32and placing it on the back of the bottom textile PCB30, and, (4) Covering the dock backing32with a fabric, preferably laminated.

FIG.20illustrates the steps108relating to assembling the connector PCB26into the bottom module enclosure24with this embodiment comprising the steps of: (1) placing and press-fitting the connector PCB target discs26into the bottom module holes79a, (3) heat staking the connector PCB26onto the dock body14a, (4) applying adhesive sealant around the connector PCB26to prevent water ingression between the body14aand the connector26.

FIG.21illustrates the steps110relating to assembling the light pipe16and magnet20and corresponding electronics22into the module top enclosure18and assembling the top18and bottom24module enclosures together with this embodiment comprising the steps of: (1) Press fitting and/or gluing the light pipe16into Module Top18, (2) Press fitting and/or gluing the magnet20into Module Top18as well as connecting the electronics22(e.g. via the PCB78together with the connector26) in order to electrically connect the conductive pathways76of the electronics22with the connectors of the connector26), (3) Assembling the Top18and Bottom24of the Module12together, and (4) Ultrasonically welding to seal the edges of the top18and bottom24module.

Other options for manufacture can include generally processes such as but not limited to:

1) the process of assembly comprises the steps of: assembling the top textile PCB onto the textile band; placing an adhesive material on the bottom size of the top textile PCB; inserting the top textile PCB inside the textile pocket by aligning the holes on the top textile PCB to the matching pre-punched rivet holes onto the textile band; placing double-sided adhesive on the bottom textile PCB and placing it on the opposite side of the textile band to the top textile PCB, also aligning to the pre-punched rivet holes in the textile band; and pressing the rivets at the same time as applying even pressure to the PCBs;

2) in regions where an electrical connection is needed, the pre-punched rivet holes in the textile band can be located such that an electrical conductive circuit in the textile band is physically in contact with the metal rivet;

3) the textile band pocket can be fabricated in such a manner as to be raised above the surface of the textile band providing just enough room for the module dock housing to fit snugly within the pocket, while also allowing it to be removed when used;

4) assembling the module dock and dock backing into the textile band; applying epoxy to the dock and placing it inside the pocket by aligning the heat stacking poles to the holes on the textile PCBs; heat staking the dock onto the textile PCB assembly; applying epoxy to the dock backing and placing it on the back of the bottom textile PCB; and covering the dock backing with a fabric, preferably laminated;

5) assembling the connector PCB into the bottom module enclosure; placing and press-fitting the connector PCB target discs into the bottom module holes; heat staking the connector PCB onto the dock; and applying adhesive sealant around the connector PCB to prevent water ingression; and/or

6) assembling the light pipe and magnet into the module top enclosure and assembling the top and bottom module enclosures together; press fitting and/or gluing the light pipe into Module Top; press fitting and/or gluing the magnet into Module Top; assembling the Top and Bottom of the Module together; and ultrasonically welding to seal the edges of the top and bottom module.

Reference is made toFIG.22, which illustrates a partially exploded view of a textile interconnection system2200, in accordance with embodiments of the present application. The textile interconnection system2200includes a textile receptacle2210coupled to a portion of a textile substrate2270and a textile docking device2250received within the textile receptacle2210.

The textile interconnection system2200may be configured to receive a controller device (not illustrated inFIG.22). The controller device may be a computing device that may be removably received by the textile interconnection system2200and may be configured to transmit data to or receive data from electronic components interconnected with or embedded in the textile substrate2270.

In some embodiments, the textile substrate2270may be a portion of a smart garment. In some embodiments, the smart garment may be formed of a knitted textile. In some other embodiments, the smart garment may be formed of other textile forms and/or techniques such as weaving, knitting (warp, weft, etc.) or the like. In some embodiments, the smart garment may include one of a knitted textile, a woven textile, a cut and sewn textile, a knitted fabric, a non-knitted fabric, in any combination and/or permutation thereof. Example structures and interlacing techniques of textiles formed by knitting and weaving are disclosed in U.S. patent application Ser. No. 15/267,818, the entire contents of which are herein incorporated by reference.

As used herein, “textile” refers to any material made or formed by manipulating natural or artificial fibres to interlace to create an organized network of fibres. Generally, textiles are formed using yarn, where yarn refers to a long continuous length of a plurality of fibres that have been interlocked (i.e. fitting into each other, as if twined together, or twisted together). Herein, the terms fibre and yarn may be used interchangeably. Fibres or yarns can be manipulated to form a textile according to any method that provides an interlaced organized network of fibres, including but not limited to weaving, knitting, sew and cut, crocheting, knotting and felting.

Different sections of a textile can be integrally formed into a layer to utilize different structural properties of different types of fibres. For example, conductive fibres can be manipulated to form networks of conductive fibres and non-conductive fibres can be manipulated to form networks of non-conductive fibers. These networks of fibres can comprise different sections of a textile by integrating the networks of fibres into a layer of the textile. The networks of conductive fibres can form one or more conductive pathways that can electrically connect sensors and actuators embedded in the smart garment for conveying data and/or power to and/or from these components.

In some embodiments described in the present application, the textile substrate2270may be configured as a network of conductive fibres for conveying data and/or power between the one or more sensor, actuators, devices, or combinations thereof.

In some embodiments, multiple layers of textile may be stacked upon each other to provide a multi-layer textile.

In the present application, “interlace” refers to fibres (either artificial or natural) crossing over and/or under one another in an organized fashion, typically alternately over and under one another, in a layer. When interlaced, adjacent fibres touch each other at intersection points (e.g. points where one fibre crosses over or under another fibre). In one example, first fibres extending in a first direction can be interlaced with second fibres extending laterally or transverse to the fibres extending in the first connection. In another example, the second fibres can extend laterally at 90° from the first fibres when interlaced with the first fibres. Interlaced fibres extending in a sheet can be referred to as a network of fibres.

In the present application, “integrated” or “integrally” refers to combining, coordinating or otherwise bringing together separate elements so as to provide a harmonious, consistent, interrelated whole. In the context of a textile, the textile can have various sections comprising networks of fibres with different structural properties. For example, a textile can have a section comprising a network of conductive fibres and a section comprising a network of non-conductive fibres. Two or more sections comprising networks of fibres are said to be “integrated” together into a textile (or “integrally formed”) when at least one fibre of one network is interlaced with at least one fibre of the other network such that the two networks form a layer of the textile. Further, when integrated, two sections of a textile can also be described as being substantially inseparable from the textile. Here, “substantially inseparable” refers to the notion that separation of the sections of the textile from each other results in disassembly or destruction of the textile itself.

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

As described, the textile interconnection system2200includes the textile receptacle2210coupled to the textile substrate2270. In some examples, the textile substrate2270may include one or more conductive or non-conductive fibers for transmitting/receiving data signals or power signals between the controller device received within the textile receptacle2210and one or more sensors, actuators, or components coupled to the textile substrate2270.

The textile receptacle2210may project from the portion of the textile substrate2270to form a cavity for receiving the controller device. In some embodiments, the textile receptacle2210may project from the portion of the textile substrate2270to form a pocket-like cavity for receiving the controller device. The textile docking device2250may be received within the textile receptacle2210and may be configured as an electrical and/or mechanical interconnection interface between the controller device and the textile substrate2270. For example, the textile docking device2250may be coupled to at least one conductive fibre of the textile substrate2270to provide an electrical interconnection with the at least one conductive fiber of the textile substrate2270. In some embodiments, the textile receptacle2210may include textile material that is substantially similar to the textile substrate2270. As such, the textile receptacle2210may be an extension that projects or protrudes from a surface of the textile substrate2270.

In some embodiments, when the textile receptacle2210receives the controller device, the textile receptacle2210may be configured as a mechanical encasing providing a physical barrier for the controller device from external elements such as moisture, physical disturbances, or other external environmental elements. For instance, the textile receptacle2210may include moisture-resistant material configured as a moisture barrier for the controller device received within the textile receptacle2210(e.g. pocket-like cavity).

In some embodiments, the portion of the textile substrate2270associated with the textile receptacle2210may be configured with traces or electrodes for integrating electronic hardware. For example, the portion of the textile substrate2270associated with the textile receptacle2210may include one or more conductive traces2212or conductive pads2214. The conductive traces2212or conductive pads2214may be inlaid on the textile substrate2270. The conductive traces2212or the conductive pads2214may be associated with the textile receptacle2210. For instance, the conductive traces2212or the conductive pads2214may be positioned on a portion of the textile substrate2270and within or proximal the pocket-like cavity of the textile receptacle2210.

The conductive pads2214may be positioned such that the conductive pads may interconnect or mate with electronic pads of the controller device, when the controller device is received within the textile receptacle2210.

The conductive traces2212or conductive pads2214may be coupled to one or more conductive fibers of the textile substrate2270, and the conductive traces2212or conductive pads2214may be configured to transmit/receive data signals or power signals between the textile substrate2270and the controller device received within the textile receptacle2210.

In some embodiments, the conductive traces2212or the conductive pads2214may be coupled to a support board2216. In some examples, the support board2216may be a printed circuit board.

In some embodiments, the portion of the textile substrate2270associated with the textile receptacle2210may include one or more mounting apertures. The mounting apertures may be configured to receive the textile docking device2250. The textile docking device2250may be a printed circuit board for interfacing with the controller device received within the textile receptacle2210.

In some embodiments, the textile substrate2270may be disposed between the textile docking device2250and the support board2216. The support board2216may provide foundational support to the textile receptacle2210. The conductive traces2212or conductive pads2214may be configured to interface the textile docking device2250and the textile substrate2270. The conductive traces2212or conductive pads2214may be configured to transmit/receive power or data signals between the textile substrate2270and the textile docking device2250.

In some embodiments, the textile docking device2250may be coupled to the textile substrate2270directly without the support circuit board2216.

In some embodiments, the textile docking device2250may be configured as an electronic circuit (e.g. a printed circuit board including conductive pads) and one or more fastener components. The fastener components may include one or more grommets2254or one or more heat stake apertures2256. The grommets2254or heat stake apertures2256may correspond to or align with apertures or other fastening features of the textile substrate2270, and the textile docking device2250may be coupled within the textile receptacle2210via one or more grommets2254or heat stake apertures2256.

The textile docking device2250may include one or more circuit connection pads2252substantially aligning with conductive traces2212or conductive pads2214positioned proximal or within the pocket-like cavity of the textile receptacle2210.

In some embodiments, the textile interconnection system2200may include a housing2218received within the textile receptacle2210. The housing2218may be configured to provide a substantially structured frame for the textile receptacle2210, and the controller device may be mechanically received within the housing2218. In some embodiments, the housing2218may be configured to provide a mechanical interconnection between the received controller device and the textile substrate2270.

In some embodiments, the textile docking device2250may be coupled or combined with the housing2218, and collectively may electrically and/or mechanically receive the controller device within the textile receptacle2210.

In some embodiments, the one or more grommets2254may be pressed or crimped, and pins (e.g. plastic pins) from the housing2218may align the textile docking device2250, the conductive traces2212/conductive pads2214, and the support circuit board2216. In some embodiments, one or more heat stakes may be inserted within one or more heat stake apertures2256to provide mechanical support for components of the textile interconnection system2200.

As described in the present application, the textile receptacle2210may receive a controller device. The controller device may be mechanically interconnected to the textile substrate2270by the housing2218and may be electronically interconnected to the textile substrate2270by the textile docking device2250. The controller device may be configured as a power supply, a power receiver/storage device, a data communication bus, a sensor platform/device, an actuator platform/device, or a combination of any of the foregoing, among other devices.

In some embodiments, the housing2218may include a magnet, positioned within the textile receptacle2210. When the controller device is received within the textile receptacle2210, including the housing2218, the magnet (not illustrated inFIG.22) may be configured to exert a magnetic attractive force for retaining the controller device within the textile receptacle2210. In some embodiments, the magnet may include a first polarity. When the controller device is received within the textile receptacle2210, the controller device may include a magnet having a second, opposing polarity to the first polarity. The controller device may be retained within the textile receptacle2210based on the attractive magnetic force provided by opposing magnetic poles.

As illustrated in embodiments described in the present application, the textile interconnection system2200may provide interconnections between the controller device and the textile substrate2270for sharing power or electronic data communications. As sensor devices, actuator devices, or other electronic devices integrated throughout the textile substrate2270may require power signals or data signals to interoperate with one or more devices connected via a network of the textile substrate2270, the textile interconnection system2200may be configured to interconnect electronic devices disparately located in the power/data network provided by the textile substrate2270. For example, the textile substrate2270may provide a plurality of disparately located sensors for obtaining physiological data (e.g. measuring impedance on surface of user skin, etc.) from a plurality of locations on a user's body. The textile interconnection system2200may provide an electrical and/or mechanical interconnection among the disparately located sensors or controller devices for collecting physiological data collected from the disparately located sensors.

In some embodiments, the textile receptacle2210may include electronic devices configured to provide intermediary communications. For example, the textile receptacle2210may include electronic devices configured as a data messaging hub or data messaging bus for coordinating data packet transmissions across conductive traces2212(e.g. a communication network). In some embodiments, the textile receptacle2210or the textile docking device2250may include data clock generation devices for generating data clock signals to synchronize data acquisition or data transfer operation. The data clock generation devices may be configured to provide reference timing signals.

Reference is made toFIG.23, which illustrates a cross sectional view of the textile interconnection system2200illustrated inFIG.22. The textile docking device2250may be combined with the housing2218and collectively may electrically and/or mechanically receive a controller device within the textile receptacle. When received within the textile receptacle2210, the housing2218may provide a substantially structured frame for the textile receptacle2210.

In some embodiments, the one or more grommets2254may be constructed of conductive material, and may conductive electrical signals to/from the support circuit board2216. In some embodiments, the one or more grommets2254may be configured to provide a vertical interconnect access (VIA) of a printed circuit board. In some embodiments, the one or more grommets2254may be configured as a vertical interconnect access to electrically interconnect the textile docking device2250and the support board2216. In some embodiments, the one or more grommets2254may be electrical ground paths for the textile docking device2250. In some embodiments, the one or more grommets2254may align with apertures or other fastening features of the textile substrate2270. In some embodiments, the one or more grommets2254may be configured as a mechanical fastener or be configured as mechanical support.

In some embodiments, the textile receptacle2210may be an extension of the textile substrate2270. The textile receptacle2210may project or protrude from a surface of the textile substrate2270.

Reference is made toFIG.24, which illustrates an underside, cross-sectional view of the textile interconnection system2200ofFIG.22. A portion of the textile substrate2270may be disposed between the textile docking device2250/housing2218and the support board2216. Further, the textile receptacle2210may project or protrude from a surface of the textile substrate2270to form a pocket-like cavity for receiving a controller device.

In some embodiments, the textile receptacle2210may project or protrude from the surface of the textile substrate2270to form the pocket-like cavity for receiving other electronic devices, such as physiological sensor devices for acquiring physiological data. For instance, the physiological sensor devices may include one-time use electrodes that may require replacement following each physiological data acquisition session.

Reference is made toFIG.25, which illustrates a perspective view of the textile interconnection system2200illustrated inFIG.22. The textile interconnection system includes the textile substrate2270and the textile receptacle2210projecting or protruding from a portion of the textile substrate2270.

In the embodiment illustrated inFIG.25, the textile receptacle2210may be a pocket-like cavity projecting from the textile substrate2270. The textile substrate2270may be a garment belt. In some embodiments, the textile receptacle2210may be knitted into the textile substrate2270and configured to be integral to the garment belt. By knitting the textile receptacle2210during production of the textile substrate2270, the textile substrate2270may be more efficiently manufactured. In comparison to methods of gluing or stitching the textile receptacle2210to the textile substrate2270after the textile substrate2270has been manufactured, knitting the textile receptacle2210during production of the textile substrate2270may result in a more durable textile receptacle2210that may not be prone to separation from the textile substrate2270due to loose stiches or deteriorating glue. Accordingly, the textile receptacle2210may be integrally knitted to the textile substrate2270.

Reference is made toFIG.26, which illustrates a top plan view of a textile interconnection system2600, in accordance with an embodiment of the present application. The textile interconnection system2600may include a textile substrate2670. The textile substrate2670may include conductive pads2614configured to transmit/receive power or data signals between the textile substrate2670and a controller device received by the textile interconnection system2600. In some embodiments, the conductive pads2614may be coupled, via conductive traces (not illustrated inFIG.26), to sensor devices, actuator devices, or other electronic components integrated or embedded throughout the textile substrate2670.

Reference is made toFIG.27, which illustrates a top plan view of a textile interconnection system2700, in accordance with another embodiment of the present application. InFIG.27, a textile substrate2770includes one or more conductive traces2712and one or more conductive pads2714inlaid in the textile substrate2270. The conductive traces2712may be configured to interconnect with one or more sensor devices2790, one or more actuator devices2792, or other electronic devices integrated or inlaid on the textile substrate2270.

Reference is made toFIG.28, which illustrates an enlarged, top plan view of conductive traces2712interconnecting with a sensor device2790and/or an actuator device2792illustrated inFIG.27.

Reference is made toFIG.29, which illustrates an enlarged, top plan view of conductive traces2712and conductive pads2714illustrated inFIG.27. InFIG.29, the illustrated conductive traces2712and conductive pads2714may be configured to substantially align with one or more circuit connection pads2252of the textile docking device2250(FIG.22). The illustrated conductive traces2712and conductive pads2714may be positioned on the portion of the textile substrate2270that may correspond to a textile receptacle of a textile interconnection system.

Reference is made toFIG.30, which illustrates a block diagram of a computing device3000, in accordance with an embodiment of the present application. As an example, a controller device that may be received by or interconnected with a substrate textile by embodiments of textile interconnection systems (e.g. textile interconnection system2200ofFIG.22) may be implemented using the example computing device3000ofFIG.30.

The computing device3000includes at least one processor3002, memory3004, I/O interface3006, and at least one network communication interface3008.

The processor3002may be a microprocessor or microcontroller, a digital signal processing (DSP) processor, an integrated circuit, a field programmable gate array (FPGA), a reconfigurable processor, a programmable read-only memory (PROM), or combinations thereof.

The memory3004may include a computer memory that may be located either internally or externally such as, for example, random-access memory (RAM), read-only memory (ROM), compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, erasable programmable read-only memory (EPROM), and electrically-erasable programmable read-only memory (EEPROM), Ferroelectric RAM (FRAM).

The I/O interface3006may enable the computing device3000to interconnect with one or more input devices, such as a keyboard, mouse, camera, touch screen and a microphone, or with one or more output devices such as a display screen and a speaker.

The network interface3008may be configured to receive and transmit data sets, for example, to a target data storage or data structures. The target data storage or data structure may, in some embodiments, reside on a computing device or system such as a mobile device.

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

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

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

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

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

Thus, it is appreciated that the optimum dimensional relationships for the parts of the invention, to include variation in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one of ordinary skill in the art, and all equivalent relationships to those illustrated in the drawings and described in the above description are intended to be encompassed by the present invention.

Furthermore, other areas of art may benefit from this method and adjustments to the design are anticipated. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.