PATENT DOCUMENT

Publication Number: US-10577732-B1
Application Number: US-201715441021-A
Country: US
Kind Code: B1

Title: Knit fabric with electrical components

Abstract:
Conductive yarns in a knitted fabric may include insulating cores covered with metal layers that form signal paths. Open circuits may be formed in the yarns by removing metal from the insulating cores at selected locations within the yarns. The fabric may be formed from rows of interlocked loops of the yarn. The open circuits may be located on the loops so that each loop with an open circuit has a first segment of the metal layer that is separated from a second segment of the layer by a portion of the loop from which the metal layer has been removed. Each electrical component may have terminals that span a respective one of the open circuits and that are shorted respectively to the metal of the first and second segments.

Claims:
What is claimed is: 
     
       1. A fabric-based item comprising:
 fabric having knit loops; and 
 an electrical component having first and second terminals coupled respectively to first and second portions of one of the loops. 
 
     
     
       2. The fabric-based item defined in  claim 1  wherein the loop to which the first and second terminals are coupled has an insulating core and a conductive coating. 
     
     
       3. The fabric-based item defined in  claim 2  wherein the conductive coating is absent from a portion of the loop between the first and second terminals. 
     
     
       4. The fabric-based item defined in  claim 1  wherein a given one of the knit loops overlaps the electrical component and the loop to which the first and second terminals are coupled. 
     
     
       5. The fabric-based item defined in  claim 4  wherein the knit loop that overlaps the component is opaque. 
     
     
       6. The fabric-based item defined in  claim 4  wherein the knit loop that overlaps the component is transparent. 
     
     
       7. The fabric-based item defined in  claim 1  wherein the first portion includes a strand of material with a polymer core coated with a metal coating to which the first terminal is shorted, wherein the second portion includes a strand of material with a polymer core with a metal coating to which the second terminal is shorted, wherein an open circuit is formed in the loop between the first and second portions, and wherein the metal coatings of the first and second portions carry a signal that passes through the electrical component. 
     
     
       8. The fabric-based item defined in  claim 7  wherein the electrical component includes a light-emitting diode. 
     
     
       9. The fabric-based item defined in  claim 7  wherein the electrical component comprises an integrated circuit. 
     
     
       10. A knit fabric, comprising:
 rows of interlocking loops of yarn, wherein the yarn includes an insulating core covered with metal; and 
 at least one electrical component having terminals that are shorted to the metal, wherein the terminals of the electrical component are coupled to the metal on opposing sides of an open circuit in the metal. 
 
     
     
       11. The knit fabric defined in  claim 10  wherein the terminals include a first terminal shorted to a first portion of a given one of the loops and a second terminal shorted to a second portion of the given one of the loops, wherein the open circuit in the metal is formed from a portion of the yarn in which the insulating core is free of the metal, and wherein the portion of the yarn that is free of the metal is between the metal of the first portion and the metal of the second portion. 
     
     
       12. The knit fabric defined in  claim 11  wherein the electrical component comprises a light-emitting diode that receives a signal that passes through the metal of the first and second portions of the given loop. 
     
     
       13. The knit fabric defined in  claim 11  wherein the electrical component comprises an integrated circuit. 
     
     
       14. The knit fabric defined in  claim 10  wherein the electrical component comprises a light-based component and wherein the open circuit in the metal comprises a portion of the yarn from which metal has been removed. 
     
     
       15. A method of forming a fabric-based item, comprising:
 knitting conductive strands of material to form a fabric with a knitting system; and 
 while knitting the conductive strands with the knitting system, forming open circuits in selected portions of the conductive strands and attaching electrical components to the conductive strands that span the open circuits so that signals that are carried by the conductive strands pass through the electrical components. 
 
     
     
       16. The method defined in  claim 15  wherein the conductive strands of material each include an insulating core covered with a metal coating and wherein forming the open circuits comprises removing the metal coating from the selected portions of the conductive strands. 
     
     
       17. The method defined in  claim 16  wherein each of the electrical components has first and second terminals that are shorted to respective first and second portions of a corresponding one of the conductive strands on opposing sides of an associated one of the open circuits. 
     
     
       18. The method defined in  claim 15  wherein knitting the conductive strands comprises forming loops in the conductive strands and wherein each of the electrical components comprises respective first and second terminals. 
     
     
       19. The method defined in  claim 18  wherein attaching the electrical components comprises attaching the first and second terminals of each of the electrical components to respective first and second portions of the loops using solder. 
     
     
       20. The method defined in  claim 15  wherein the electrical components include light-emitting diodes and wherein attaching the electrical components comprises attaching the electrical components that include the light-emitting diodes.

Description:
This patent application claims the benefit of provisional patent application No. 62/300,236, filed on Feb. 26, 2016, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD 
     This relates generally to fabric-based items and, more particularly, to fabric-based items with electrical components. 
     BACKGROUND 
     It may be desirable to form bags, furniture, clothing, and other items from materials such as fabric. Fabric-based items generally do not include electrical components. It may be desirable, however, to incorporate electrical components into a fabric-based item to provide a user of a fabric-based item with enhanced functionality. 
     It can be challenging to incorporate electrical components into a fabric-based item. Fabric is flexible, so it can be difficult to mount structures to fabric. Electrical components must be coupled to signal paths, but it can be difficult to satisfactorily attach components to conductive strands of material. 
     SUMMARY 
     A fabric-based item may include fabric such as knitted fabric. The knitted fabric may be formed from conductive yarns and insulating yarns. Conductive yarns may form signal paths and may include insulating cores covered with conductive coatings such as metal coatings. 
     Open circuits may be formed in the yarns by removing metal from the insulating cores at selected locations within the yarns. Each loop with an open circuit will have a first portion of the metal that is electrically isolated from a second portion of the metal by a gap. Electrical components can be coupled to loops. Each electrical component may span a respective open circuit in a loop and may have a first terminal that is coupled to the first portion of metal in the loop and a second terminal that is coupled to the second portion of metal in the loop. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an illustrative fabric-based item in accordance with an embodiment. 
         FIG. 2  is a top view of illustrative knitted fabric of the type that may be provided with electrical components in accordance with an embodiment. 
         FIG. 3  is a diagram of an illustrative knitting system in accordance with an embodiment. 
         FIG. 4  shows how a latch needle may hold a knit loop of yarn in a fabric in accordance with an embodiment. 
         FIG. 5  shows how the latch in the needle of  FIG. 4  may be opened as the needle is advanced through the loop in accordance with an embodiment. 
         FIG. 6  shows how a component mounting tool may be advanced towards a loop in accordance with an embodiment. 
         FIG. 7  shows how a hook on the component mounting tool may hold the loop in accordance with an embodiment. 
         FIG. 10  shows how an electrical component may be mounted to a loop in accordance with an embodiment. 
         FIG. 11  shows how the needle may be introduced to the loop while the component mounting tool is holding the loop in accordance with an embodiment. 
         FIG. 12  shows how the component mounting tool may be retracted while the needle is holding the loop in accordance with an embodiment. 
         FIG. 13  shows how the needle may be advanced after retracting the component mounting tool in accordance with an embodiment. 
         FIG. 14  is a diagram showing how a hook on the needle may receive a yarn in accordance with an embodiment. 
         FIGS. 15, 16, 17, and 18  are diagrams showing how the hook with the received yarn may be used to form a new loop in accordance with an embodiment. 
         FIGS. 19, 20, 21, and 22  show how a component mounting tool with a sheath or other structures for forming an open circuit may have a hook that forms a loop in accordance with an embodiment. 
         FIGS. 23, 24, and 25  show how an open circuit may be formed in the loop by removing a metal coating layer from a portion of a dielectric core in accordance with an embodiment. 
         FIGS. 26, 27, 28, and 29  show how a component may be mounted to the loop in a location that spans the open circuit in accordance with an embodiment. 
         FIGS. 30, 31, 32, 33, 34, and 35  show how an electrical component can be attached to a loop that is placed behind another loop in a knit fabric in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Items such as item  10  of  FIG. 1  may be based on fabric. Item  10  may be an electronic device or an accessory for an electronic device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wristwatch device, a pendant device, a headphone or earpiece device, a device embedded in eyeglasses or other equipment worn on a user&#39;s head, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which fabric-based item  10  is mounted in a kiosk, in an automobile, airplane, or other vehicle, other electronic equipment, or equipment that implements the functionality of two or more of these devices. If desired, item  10  may be a removable external case for electronic equipment, may be a strap, may be a wrist band or head band, may be a removable cover for a device, may be a case or bag that has straps or that has other structures to receive and carry electronic equipment and other items, may be a necklace or arm band, may be a wallet, sleeve, pocket, or other structure into which electronic equipment or other items may be inserted, may be part of a chair, sofa, or other seating (e.g., cushions or other seating structures), may be part of an item of clothing or other wearable item (e.g., a hat, belt, wrist band, headband, shirt, pants, shoes, etc.), or may be any other suitable fabric-based item. 
     Item  10  may include intertwined strands of material (yarns) that form fabric  12 . Fabric  12  may form all or part of a housing wall or other layer in an electronic device, may form internal structures in an electronic device, or may form other fabric-based structures. Item  10  may be soft (e.g., item  10  may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., the surface of item  10  may be formed from a stiff fabric), may be coarse, may be smooth, may have ribs or other patterned textures, and/or may be formed as part of a device that has portions formed from non-fabric structures of plastic, metal, glass, crystalline materials, ceramics, or other materials. 
     The strands of material in fabric  12 , which may sometimes be referred to herein as yarns, may be single-filament strands (sometimes referred to as fibers or monofilaments) or may be strands of material formed by intertwining multiple monofilaments of material together. 
     The yarns in fabric  12  may be formed from polymer, metal, glass, graphite, ceramic, natural materials such as cotton or bamboo, or other organic and/or inorganic materials and combinations of these materials. Conductive coatings such as metal coatings may be formed on non-conductive material. For example, plastic yarns in fabric  12  may be coated with metal to make them conductive. Reflective coatings such as metal coatings may be applied to make yarns reflective. Yarns may be formed from bare metal wires or metal wire intertwined with insulating monofilaments (as examples). Bare metal strands and strands of polymer covered with conductive coatings may be provided with insulating polymer jackets. 
     Yarn may be intertwined to form fabric  12  using intertwining equipment such as weaving equipment, knitting equipment, or braiding equipment. Intertwined yarn may, for example, form knitted fabric. Conductive yarn and insulating yarn may be woven, knit, braided, or otherwise intertwined to form contact pads that can be electrically coupled to conductive structures in item  10  such as the contact pads of an electrical component. 
     Conductive yarn and insulating yarn may also be woven, knit, or otherwise intertwined to form conductive paths. The conductive paths may be used in forming signal paths (e.g., signal buses, power lines, etc.), may be used in forming part of a capacitive touch sensor electrode, a resistive touch sensor electrode, or other input-output device, or may be used in forming other patterned conductive structures. Conductive structures in fabric  12  may be used in carrying power signals, digital signals, analog signals, sensor signals, control signals, data, input signals, output signals, or other suitable electrical signals. 
     Item  10  may include additional mechanical structures  14  such as polymer binder to hold yarns in fabric  12  together, support structures such as frame members, housing structures (e.g., an electronic device housing), and other mechanical structures. 
     To enhance mechanical robustness and electrical conductivity at yarn-to-yarn connections, additional structures and materials (e.g., solder, crimped metal connections, welds, conductive adhesive such as anisotropic conductive film and other conductive adhesive, non-conductive adhesive, fasteners, etc.) may be used to help form yarn-to-yarn connections. These yarn-to-yarn connections may be formed where yarns cross each other perpendicularly or at other yarn intersections where connections are desired. Insulating material can be interposed between intersecting conductive yarns at locations in which it is not desired to form a yarn-to-yarn connection. The insulating material may be plastic or other dielectric, may include an insulating yarn or a conductive yarn with an insulating coating, etc. Solder connections may be formed between conductive yarns by melting solder so that the solder flows over conductive yarns. The solder may be melted using an inductive soldering head to heat the solder, using a reflow oven to heat the solder, using a laser or hot bar to heat the solder, or using other soldering equipment. During soldering, outer dielectric coating layers (e.g., outer polymer layers) may be melted away in the presence of molten solder, thereby allowing underlying metal yarns to be soldered together. 
     Circuitry  16  may be included in item  10 . Circuitry  16  may include electrical components that are coupled to fabric  12 , electrical components that are housed within an enclosure formed by fabric  12 , electrical components that are attached to fabric  12  using welds, solder joints, conductive adhesive bonds, crimped connections, or other electrical and/or mechanical bonds. Circuitry  16  may include metal structures for carrying current, electrical components such as integrated circuits, light-emitting diodes, sensors, and other electrical devices. Control circuitry in circuitry  16  may be used to control the operation of item  10 . 
     Item  10  may interact with electronic equipment or other additional items  18 . Items  18  may be attached to item  10  or item  10  and item  18  may be separate items that are configured to operate with each other (e.g., when one item is a case and the other is a device that fits within the case, etc.). Control circuitry in circuitry  16  may be used to support communications with item  18  and/or other devices. Circuitry  16  may include antennas and other structures for supporting wireless communications with item  18 . Item  18  may also interact with item  10  using a wired communications link or other connection that allows information to be exchanged. 
     In some situations, item  18  may be an electronic device such as a cellular telephone, computer, or other portable electronic device and item  10  may form a cover, case, bag, item of clothing, or other structure that receives the electronic device in a pocket, an interior cavity, or other portion of item  10 . In other situations, item  18  may be a wristwatch device or other electronic device and item  10  may be a strap or other fabric-based item that is attached to item  18  (e.g., item  10  and item  18  may together form a fabric-based item such as a wristwatch with a strap). In still other situations, item  10  may be an electronic device, fabric  12  may be used in forming the electronic device, and additional items  18  may include accessories or other devices that interact with item  10 . Signal paths formed from conductive yarns may be used to route signals in item  10  and/or item(s)  18 . 
     The fabric that makes up item  10  may be formed from multifilament and/or monofilament yarns (strands) that are intertwined using any suitable intertwining equipment. With one suitable arrangement, which may sometimes be described herein as an example, fabric  12  may be knitted fabric formed using a knitting machine. A top view of illustrative knitted fabric  12  is shown in  FIG. 2 . In the illustrative configuration of  FIG. 2 , fabric  12  has a single layer of knitted yarns  24 . Other fabric constructions may be used for fabric  12  if desired. 
     As shown in  FIG. 2 , fabric  12  may include yarns  24  or other strands of material that form horizontally extending rows of interlocking loops (courses  22 ) and vertically extending wales  20 . Some or all of yarns  24  in fabric  12  such as yarn  24  in course  22 ′ in the example of  FIG. 2  may be conductive. 
     Some or all of the loops of conductive yarn in fabric  12  may be provided with electrical components such as illustrative component  26 . Components in fabric  12  such as component  26  may be light-based components (e.g., light-emitting diodes and/or light detectors), may be sensors that sense temperature, pressure, force, capacitance, touch, magnetic field strength, motion, other suitable sensors, integrated circuits with sensors and/or light-based components, integrated circuits with communications circuitry and/or control circuitry, and/or other electrical devices. 
     Components such as component  26  may have any suitable number of terminals. For example, component  26  may have a pair of terminals such as terminals  28 . Component  26  may be mounted to yarn loop  30  so that a first of terminals  28  is electrically shorted to yarn loop portion  30 - 1  and a second of terminals  28  is electrically shorted to yarn loop portion  30 - 2 . For example, solder or other conductive material may be used to couple terminals  28  to metal in yarn portions  30 - 1  and  30 - 1 . 
     The metal or other conductive material of yarn  24  in course  22 ′ may be selectively removed in the vicinity of component  26  between portions  30 - 1  and  30 - 2  to create an open circuit such as open circuit  34 . In the presence of open circuit  34 , signals can pass through component  26  (i.e., signals can pass from one terminal of component  26  to the other), but will not pass through the portion of loop  30  that extends between yarn loop portion  30 - 1  and yarn loop portion  30 - 2 . The formation of open circuit  34  therefore ensures that terminals  28  will not be shorted to each other by yarn  24  and allows component  26  to operate satisfactorily. Control circuitry in circuitry  16  ( FIG. 1 ) may be used in controlling the application of signals to component  26  via yarn  24 . 
     Knitted fabric such as knitted fabric  12  of  FIG. 2  may be formed using any suitable knitting equipment. An illustrative knitting system for forming fabric  12  is shown in  FIG. 3 . As shown in  FIG. 3 , knitting equipment such as knitting system  50  may include a yarn source such as yarn source  40 . Yarn source  40  may include a creel with spools of yarn  24 . Knitting elements  42  may be used to knit yarn  24  into knitted fabric  12  while forming open circuits  34  and attaching electrical components  26  to selected loops of yarn  24 , as described in connection with  FIG. 2 . Knitted fabric  12  may be gathered on drums or other take-down equipment  48 . 
     Knitting elements  42  may include yarn guide structures such as feeders  44  that guide yarn  24  towards needles and other equipment  46 . Equipment  46  may include latch needles or needles of other types, may include feeders for mounting components  26  on yarn  24 , and may include cutting tools or other equipment for forming open circuits in yarn  24  (see, e.g., open circuit  34  of  FIG. 2 ). Equipment  46  may include cam structures and other structures for manipulating the positions of needles, component mounting feeders, and/or cutting tools or other tools for open circuit formation. The needles, feeders, and tools for forming open circuits in yarn  24  may be implemented as separately adjustable components or the functionality of two or more of these tools may be combined in equipment  46 . For example, a component feeder may include open circuit formation structures such as cutting structures for selectively removing metal from yarn  24 . Equipment such as feeders  44  and equipment  46  (i.e., knitting elements  42 ) may sometimes be referred to as knitting equipment, knitting and component mounting equipment, equipment for knitting, component mounting, and open circuit formation, etc. 
     The use of a knitting system such as knitting system  50  of  FIG. 3  to knit fabric  12  with components  26  and open circuits  34  is described in the examples of  FIGS. 4-35 . Other techniques for forming open circuits  34  and for mounting components  26  to loops in fabric  12  may be used, if desired. 
       FIG. 4-18  show how system  50  may be used to knit fabric  12  while installing components  26  onto loops  30  of fabric  26 . In the drawings of  FIGS. 4-18 , latch needle  54  and component mounting tool  68  (e.g., one of needles  46  and one of the component feeders of  FIG. 3 ) are used to knit yarn  24  into fabric  12  while attaching components  26 . As shown in  FIG. 4 , latch needle  54  includes a stem (shaft) such as stem  56  having a protruding portion that forms butt  58 . Latch  60  is mounted to stem  56  using pivot  62 . Latch needle  54  has a hook such as hook  64  that is formed from a bent tip portion of stem  56 . Latch  60  may be moved between a closed position (as shown in  FIG. 4 ) and an open position by pivoting latch  60  about pivot  62 . 
     In the needle position of  FIG. 4 , loop  30  has been formed by needle  54 , latch  60  is closed, and loop  30  is held in closed hook  64 . 
     As shown in  FIG. 5 , as needle  54  is advanced in direction  66 , loop  30  presses against latch  60  and opens latch  60 . 
     Equipment  46  may include component mounting tools such as component mounting tool  68  of  FIG. 6 . Component mounting tool  68  may have a shaft such as shaft  70 . Hook  72  may be formed at the end of shaft  70 . Component mounting tool  68  may have component mounting structures for dispensing components  26  and attaching the terminals of components  26  to yarn  24 . Tool  68  may, for example, include positioning equipment for moving components  26  into place and may have electrical connection formation equipment for forming electrical connections between components  26  and yarn  24 . The positioning equipment may include structures that are powered by pressurized air, by vacuum suction, by electromagnetic actuators, by cams and other structures that convert translating movement of equipment such as needles, component feeders, and cutting tools into vertical movement, by electromagnets, and/or by other structures for positioning components  26  on yarn  24 . The electrical connection formation equipment may include equipment for forming solder connections, welds, and cured conductive adhesive connections such as hot bar soldering structures, reflow oven structures, heat lamps, lasers, and other sources of heat and/or equipment for dispensing solder, adhesive, etc. 
     As shown in  FIG. 7 , when component mounting tool  68  is advanced in direction  74 , hook  72  of component mounting tool  68  may engage loop  30 . 
     Once hook  72  has grasped the yarn of loop  30 , needle  54  may be retracted in direction  76 , causing loop  30  to press against latch  60  and thereby close latch  60  as shown in  FIG. 8 . 
     As shown in  FIG. 9 , after needle  54  has been completely retracted in direction  76 , needle  54  will be clear of loop  30  and loop  30  will be held in place by hook  72  of component mounting tool  68  rather than hook  64  of needle  54 . 
     As shown in  FIG. 10 , component mounting tool  68  may couple a component  26  to loop  30  (e.g., using solder, welds, conductive adhesive, etc.) while hook  72  is holding loop  30 , so that terminals  28  of component  26  form electrical connections to the left and right halves of loop  30 , as described in connection with  FIG. 2 . An open circuit such as open circuit  34  of  FIG. 2  may then be formed in loop  30 , as described in more detail in connection with  FIGS. 19-29 . 
     After mounting component  26  to loop  30  (and forming open circuit  34 ) as shown in  FIG. 10 , needle  54  can again be advanced in direction  66 , as shown in  FIG. 11 . This causes hook  64  to pass through loop  30  and causes latch  60  to open as the yarn of loop  30  presses against latch  60 . 
     As shown in  FIG. 12 , needle  54  may hold loop  30  in position while component mounting tool  68  is retracted in direction  78 . 
     After retracting component mounting tool  68 , needle  54  may be advanced farther in direction  66  until butt  58  presses against loop  30 , as shown in  FIG. 13 . Another yarn  24  may then be received by hook  64  of needle  54 , as shown in  FIG. 14 . 
     Retraction of needle  54  in direction  76  cause the yarn of loop  30  to press against latch  60 , thereby closing latch  60  against hook  64  to retain the newly received yarn  24  within hook  64 , as shown in  FIG. 15 . 
     Further retraction of needle  54  in direction  76  causes latch  60 , hook  64 , and the yarn held by hook  64  to pass through loop  30 , as shown in  FIG. 16 . Needle  54  may then be advanced in direction  66  to form a new loop of yarn  24  such as new loop  30 N of  FIG. 17 . When needle  54  reaches the position of  FIG. 18 , a knitting cycle has been completed (i.e., the fabric and needle configuration of  FIG. 18  is the same as that of  FIG. 4 ). Further cycles may be performed (with our without component mounting using tool  68 ) until the knitting of fabric  12  is complete. 
     Open circuits such as open circuit  34  of  FIG. 2  may be formed during the knitting operations of  FIGS. 4-16 . Open circuit formation operations are illustrated separately in  FIGS. 19-29  for clarity. 
     When forming fabric  12 , some of yarns  24  may be conductive (e.g., those yarns onto which it is desired to mount components  26 ). Remaining yarns  24  may be either conductive or non-conductive. As shown in  FIG. 19 , conductive yarn  24  in loop  30  may be formed using an insulating portion such as insulating core  84  and a conductive portion such as metal layer  82  or other conductive coating. Strands of material in fabric  12  may have a single filament (as shown by yarn  24  in  FIG. 19 ) or may have multiple filaments. 
     Component mounting tool  68  may include open circuit formation capabilities. For example, conductive yarns may have insulating polymer cores or other strands of dielectric covered with a conductive metal coating. Tool  68  may include a metal remover such as metal remover  80 . Metal remover  80  may use heat, light (e.g., laser light), electricity, abrasion, cutting (wire stripping motions), or other suitable techniques to selectively remove a portion of the conductive metal coating away from an insulating polymer core in the yarn of loop  30  to form open circuit  34 . As an example, metal remover  80  may be formed from a metal sheath with a sharp leading edge such as cutting edge  86  in the example of  FIG. 19  that can advance towards hook  72  at the end of shaft  70  of tool  68  or that can retract away from hook  72 . The use of a tool such as component mounting tool (and open circuit formation tool)  68  of  FIG. 19  may sometimes be described herein as an example. In general, equipment  46  of system  50  may use any suitable tool for attaching components  26  to loops  30  and for forming open circuits  34  in loops  30 . Tool  68  of  FIG. 19  is merely illustrative. 
     Initially, tool  68  may be in a retracted position so that loop  30  is not received within hook  72  ( FIG. 19 ). 
     As shown in  FIG. 20 , tool  68  may be advanced towards loop  30  in direction  74  so that hook  72  can receive loop  30  ( FIG. 21 ). Tool  68  may then be retracted in direction  78  to enlarge loop  30 , as shown in  FIG. 22 . 
     After forming loop  30 , metal remover  80  may remove a portion of metal coating  82  in a localized area of loop  30  to form open circuit  34 . As shown in  FIG. 23 , for example, metal remover  80  may be a metal sheath this is advanced over shaft  70  and hook  72  of tool  68  until cutting edge  86  of the sheath cuts away coating  82  from yarn  24 . This leaves a portion of yarn  24  in loop  30  between loop portions  30 - 1  and  30 - 2  free of metal coating  82  (i.e., a gap is formed in metal coating  82 ), thereby forming open circuit  34 , as shown in  FIG. 24 . The metal sheath may then be retracted in direction  78  to expose hook  72  and the tip of shaft  70 , as shown in  FIG. 25 . 
       FIGS. 26, 27, and 28  show how component  26  may be advanced along tool  68  and mounted on loop  30 , as described in connection with  FIGS. 9 and 10 . Soldering, welding, conductive adhesive attachment techniques, crimping, or other suitable techniques may be used to attach and thereby short terminals  28  of component  26  to the conductive material (metal coating  82 ) in yarn  24  of loop  30 . 
       FIG. 29  shows how loop  30  may appear after component  26  has been mounted to loop  30 . The presence of open circuit  32  allows signals to be conveyed through component  26  using the conductive metal coating on the left and right sections of yarn  24 . 
     If desired, fabric  12  may be formed from multiple yarns  24  and techniques such as intarsia and plating may be used to create fabric  12  in which components  26  are located and/or made visible in selected portions of fabric  12 . For example, in an intarsia scheme, components  26  may be attached to a first yarn and not to a second yarn. Areas of fabric  12  in which it is desired to include components  26  may be formed using the first yarn. Areas of fabric  12  in which it is not desired to include components  26  may be formed using the second yarn. 
     As another example, a plating technique of the type shown in  FIGS. 30-35  may be used to form fabric  12 . Using this technique, components  26  on the first yarn may be hidden from view in some areas of fabric  12  by placing the second yarn in front of the first yarn and may be exposed to view in other areas of fabric  12  by placing the first yarn in front of the second yarn (as an example). 
     As shown in  FIG. 30 , needles  54 A and  54 B may be used in knitting fabric  12  from first yarn  24 A and second yarn  24 B. Components  26  may be mounted on first yarn  24 A using component mounting tool  68 . Component mounting tool  68  may then be retracted in direction  78  ( FIGS. 31 and 32 ). 
     As shown in  FIG. 33 , left needle  54 A may be advanced so that latch  60 A of needle  54 A clears loop  30 B of yarn  24 B and so that butt  58 A of needle  54 A advances yarn  24 B to a position where loop  30 B of yarn  24 B may be grasped by hook  64 B of needle  54 B. Needle  54 A may then be retracted ( FIG. 34 ). 
     As shown in  FIG. 35 , in completed fabric  12 , loops formed from second yarn  24 B such as loop  30 B may be placed in front of loops formed from first yarn  24 A such as loop  30 A. Components  26  are mounted on loops  30 A, so the arrangement of  FIG. 35  allows second yarn loops  30 B to cover components  26  on loops  30 A (i.e., the layer of knitted fabric  12  formed from loops  30 B will be on the outside of fabric  12  and will be visible to a user, whereas the layer of knitted fabric  12  formed from loops  30 A and components  26  on loops  30 A will be on the inside of fabric  12  and will not be visible to a user). If desired, the relative positions of loops  30 A and  30 B (and therefore the exposure of components  26 ) may be varied as a function of position in fabric  12 . In some areas, components  26  may be hidden from view by an exterior layer of knitted loops, whereas in other areas, components  26  may be exposed to view and may be uncovered (i.e., not covered by loops  30 B). 
     When hiding components  26 , loops  30 B may be formed from opaque material on the outside of fabric  12  that blocks underlying loops  30 A on the inside of fabric  12  from view. If desired, loops  30 B may be formed from transparent material (e.g., clear low-haze material, translucent material, colored transparent material, etc.). In this type of configuration, light that has been emitted by components  26  (e.g., light-based components such as light-emitting diodes) may pass through overlapping loops  30 A or light that has passed through loops  30 A may be received by components  26  (e.g., light-based components such as light detectors). If desired, some of the loops in fabric  12  may be formed from opaque material and some of the loops in fabric  12  may be formed from transparent material. Configurations in which all of yarns in fabric  12  are opaque or are transparent may also be used. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20170223
Publication Date: 20200303
Grant Date: 20200303
Priority Date: 20160226
Inventors: PODHAJNY, DANIEL A.
SUNSHINE, Daniel D.
HAMADA, Yohji
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2201/10106", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0281", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/0108", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/038", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21S4/15", "inventive": true, "first": true, "tree": "[]"}, {"code": "F21Y2115/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04B21/14", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/111", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21V23/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/038", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21V19/0025", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21V33/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/341", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10106", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10106", "inventive": false, "first": false, "tree": "[]"}, {"code": "F21V23/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/038", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/341", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21V19/0025", "inventive": true, "first": false, "tree": "[]"}, {"code": "F21V33/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D04B21/14", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/111", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2403/02431", "inventive": false, "first": false, "tree": "[]"}, {"code": "D10B2401/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "D10B2401/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04B1/12", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 69645538