PATENT DOCUMENT

Publication Number: US-11233012-B2
Application Number: US-201816134839-A
Country: US
Kind Code: B2

Title: Fabric-based items having strands with embedded components

Abstract:
A fabric-based item may include fabric formed from intertwined strands of material with embedded circuitry. The strands of material may be formed from dielectric materials such as polymers. The strands of material may be formed from joined segments of polymer strand material or other material. Each joined segment may contain a potentially distinct circuit. Some joined segments may include one or more conductive lines. The conductive lines may run parallel to each other along the length of the joined segments to form circuit interconnects. Conductive lines may be joined to contact pads on integrated circuits and other embedded components formed from semiconductor dies. Control circuitry formed from the integrated circuits embedded in strands of material in the fabric and other control circuitry may be used to control the circuitry embedded in the fabric.

Claims:
What is claimed is: 
     
       1. A fabric-based item, comprising:
 fabric formed from intertwined strands of material including a strand of material with multiple joined strand segments, wherein the joined strand segments include electrically interconnected electrical devices embedded within polymer strand material, wherein the polymer strand material has a longitudinal axis, wherein the joined strand segments comprise first strand segments and second strand segments, wherein each of the first strand segments and the second strand segments comprises at least two parallel conductive lines embedded in the polymer strand material, and wherein each of the conductive lines has a longitudinal axis that is parallel to the longitudinal axis of the polymer strand material; and 
 control circuitry configured to control the electrically interconnected electrical components. 
 
     
     
       2. The fabric-based item defined in  claim 1  wherein the first strand segments have semiconductor dies that are joined by the second strand segments, and wherein the second strand segments have embedded conductive lines that are electrically coupled to contacts on the semiconductor dies. 
     
     
       3. The fabric-based item defined in  claim 2  wherein each of the semiconductor dies has opposing first and second sides, a first contact on the first side that is coupled to a first of the embedded conductive lines, and a second contact on the second side that is coupled to a second of the embedded conductive lines. 
     
     
       4. The fabric-based item defined in  claim 3  wherein the first and second conductive lines comprise respective first and second metal lines that are bonded respectively to the first and second contacts. 
     
     
       5. The fabric-based item defined in  claim 2  wherein the at least two parallel conductive lines embedded in the polymer strand material run along the strand of material having the joined strand segments. 
     
     
       6. The fabric-based item defined in  claim 5  wherein the semiconductor dies include light-emitting devices. 
     
     
       7. The fabric-based item defined in  claim 5  wherein the semiconductor dies include integrated circuit dies. 
     
     
       8. The fabric-based item defined in  claim 1  wherein each of the first strand segments contains an embedded conductive line and the second strand segments are electrically coupled to the first strand segments. 
     
     
       9. The fabric-based item defined in  claim 8  wherein the second strand segments each include a semiconductor die with a light-emitting device. 
     
     
       10. The fabric-based item defined in  claim 8  wherein the second strand segments each include a sensor. 
     
     
       11. The fabric-based item defined in  claim 8  wherein the second strand segments each include a haptic output device. 
     
     
       12. The fabric-based item defined in  claim 1  wherein the control circuitry comprises an integrated circuit embedded in the polymer strand material of the joined strand segments. 
     
     
       13. A fabric-based item, comprising:
 fabric comprising:
 intertwined polymer strands that each has first strand segments joined to second strand segments, wherein the first and second strand segments each have rotational alignment structures including protrusions and recesses configured to rotationally align the first strand segments and the second strand segments; and 
 electrical components embedded in the polymer strands, wherein the electrical components have contact pads that are electrically connected to conductive lines embedded in the polymer strands; and 
 
 control circuitry configured to control the electrical components. 
 
     
     
       14. The fabric-based item defined in  claim 13  wherein the electrical components comprise integrated circuit dies and wherein the conductive lines are bonded to the contact pads. 
     
     
       15. The fabric-based item defined in  claim 14  wherein the first strand segments each include a respective one of the electrical components. 
     
     
       16. The fabric-based item defined in  claim 15  wherein the second strand segments each include a respective one of the conductive lines. 
     
     
       17. A strand of dielectric material formed from joined segments, the strand comprising:
 first strand segments that each include first and second parallel metal lines embedded in first polymer strand material, wherein the first polymer strand material has a longitudinal axis, and wherein the first and second metal lines each have a longitudinal axis that is parallel to the longitudinal axis of the first polymer strand material; and 
 second strand segments that each include a semiconductor die embedded in second polymer strand material. 
 
     
     
       18. The strand of dielectric material defined in  claim 17  wherein the first strand segments each include a third parallel metal line that is embedded in the first polymer strand material and runs parallel to the first and second parallel metal lines of that strand segment. 
     
     
       19. The strand of dielectric material defined in  claim 18  wherein the first and second strand segments have circular cross-sectional shapes with rotational alignment structures.

Description:
This application claims the benefit of provisional patent application No. 62/645,079, filed Mar. 19, 2018, 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 having strands of material with embedded components. 
     BACKGROUND 
     It may be desirable to form bags, furniture, clothing, wearable electronic devices, and other items using fabric. In some arrangements, it may be desirable to incorporate electrical circuitry into fabric. If care is not taken, however, fabric-based items may not offer desired features. For example, fabric-based items may not include desired circuitry for providing a user with output or gathering input or may include circuitry that is bulky, heavy, and unattractive. 
     SUMMARY 
     A fabric-based item may include fabric formed from intertwined strands of material with embedded circuitry. The fabric-based item may include woven fabric, knit fabric, or other fabric. The circuitry in the fabric-based item may gather input from a user and from the user&#39;s surroundings. The circuitry may supply visual output, audio output, tactile output, and/or other output. 
     The strands of material may be formed from dielectric materials such as polymers. The strands of material may be formed from joined segments of polymer strand material or other material. Each joined segment may contain a potentially distinct circuit embedded within the polymer strand material. Computer-controlled assembly equipment may select and join customized collections of strand segments to form a strand or set of strands in the fabric to implement desired circuit functions. 
     Strand segments may include thermoplastic material and may be thermally joined or joined using other joining techniques. Some joined strand segments may include one or more conductive lines. The conductive lines may run parallel to each other along the length of the joined segments to form circuit interconnects. Conductive lines may be bonded to contact pads on integrated circuits and other embedded components formed from semiconductor dies. The semiconductor dies may have surface normals that extend parallel to the strands. Control circuitry formed from the integrated circuits embedded in strands of material in the fabric or other control circuitry may be used to control input-output components and other electrical components embedded in the fabric. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an illustrative system with one or more items in accordance with an embodiment. 
         FIG. 2  is side view of illustrative fabric in accordance with an embodiment. 
         FIG. 3  is a side view of an illustrative strand of material formed from a series of joined strand segments in accordance with an embodiment. 
         FIG. 4  is a cross-sectional end view of an illustrative strand of material with embedded conductive lines in accordance with an embodiment. 
         FIG. 5  is a cross-sectional end view of an illustrative strand of material such as a strand of tubing in accordance with an embodiment. 
         FIG. 6  is a cross-sectional end view of an illustrative strand of material with an electrical component in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of an illustrative strand of material with an embedded conductive line in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of the illustrative strand of material of  FIG. 8  after treatment to expose an end portion of the conductive line in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of an illustrative pair of strand segments such as the strands segment of  FIG. 8  being coupled to a component associated with an additional segment in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative strand formed using the process of  FIG. 9  in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative strand of material having multiple conductive paths joined to contacts on an electrical component in accordance with an embodiment. 
         FIG. 12  is a cross-sectional side view of an illustrative strand having multiple segments with different respective circuits in accordance with an embodiment. 
         FIGS. 13, 14, and 15  are cross-sectional end views of illustrative strands with rotational alignment features in accordance with embodiments. 
         FIG. 16  is a perspective view of a pair of strands having respective protruding and recessed alignment features in accordance with an embodiment. 
         FIG. 17  is a cross-sectional side view of a branching strand in accordance with an embodiment. 
         FIG. 18  is a cross-sectional side view of illustrative strand fabrication equipment in accordance with an embodiment. 
         FIG. 19  is a diagram showing illustrative equipment of the type that may be used in forming items in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Items may incorporate strands of material. The strands of material can be incorporated into wearable items and other items. In some arrangements, fabric formed from strands of material may be used in forming clothing, straps, bags, enclosures, electronic device housing structures, and other fabric-based items. Circuitry can be incorporated into the items by embedding conductive lines, electrical components, and other circuits into strands of material. Segments of the strands can be joined in desired patterns to form more complex circuits. The circuitry embedded in the strands can be used to gather sensor input (e.g., touch input, force input, etc.) and/or can be used to supply output (e.g., light, sound, haptic output, electrical output, acoustic output, etc.). 
       FIG. 1  is a schematic diagram of a system with one or more illustrative items  10 . As shown in  FIG. 1 , system  8  has at least one item  10 . If desired, item  10  may interact with other items  10  via wired and/or wireless paths such as path  18 . For example, a first item  10  may be a strap for a wristwatch and a second item  10  may be a metal watch unit that is coupled to the strap. 
     Each item  10  may include control circuitry  12 . Control circuitry  12  may be formed from circuitry such as electrical components  16  (e.g., one or more integrated circuits such as microprocessors, microcontrollers, application-specific integrated circuits, digital signal processors, etc.). Control circuitry  12  may be used to control the operation of item  10  by controlling electrically controllable (electrically adjustable) components in item  10  and may be used to support communications with other items  10  (e.g., via paths such as path  18 ). 
     Item  10  may include input-output circuitry such as input-output devices  14 . Devices  14  (and circuitry  12 ) may include one or more electrical components  16  (e.g., integrated circuits, semiconductor die, discrete components such as resistors, inductors, and capacitors, etc.). Input-output devices  14  may include components for providing a user of item  10  with output (e.g., light-emitting diodes, lasers, and other light-producing components for emitting light as part of a pixel array of other output device, audio transducers, haptic output devices such as piezoelectric devices for producing haptic output (e.g., vibrations), antennas for transmitting wireless signals, communications circuits for transmitting data over wired communications links, etc.). 
     Input-output devices  14  may also include components for gathering input from a user and from a user&#39;s surroundings. Devices  14  may, for example, include temperature sensors, pressure sensors, force sensors, gas sensors (e.g., carbon monoxide sensors), particulate sensors, moisture sensors, light sensors, magnetic sensors, capacitive sensors (e.g., sensors for touch or proximity measurements), gesture sensors, image sensors, proximity sensors, touch sensors, button sensors (e.g., switches coupled to movable button members or button regions), sensors that gather other types of input and/or hybrid sensors that include sensor functionality from any two or more of these sensors. Input and output can also be provided using accessories (e.g., other items  10  such as pointing devices, etc.). Wireless communications can be supported by wireless transceiver circuitry and antennas in devices  14 . If desired, multiple components  16  can be used together. For example, multiple captive sensor devices may be used together in an array in item  10  to form a two-dimensional touch sensor. As another example, multiple light-emitting diodes or lasers may be used to form a pixel array that is configured to display images for a user. 
     Item  10  can include strands of material. The strands of material may be embedded in polymer or other binder, may be free of binder, may be intertwined to form fabric, or may be otherwise incorporated into item  10 . Strands can be formed from polymer, metal, glass, and/or other materials. In some configurations, strands of material in item  10  include multiple types of material (e.g., embedded conductive paths formed from metal wires, polymer, etc.). Wires can be insulating (e.g., when formed of plastic, glass, or other dielectric) and/or may be conductive (e.g., when a polymer strand is coated with a metal layer and/or one or more metal lines is coated with polymer to form a strand). 
     Illustrative strands of material for item  10  are shown in  FIG. 2 . In the example of  FIG. 2 , strands  20  have been intertwined together to form fabric  22 . Strands  20  may include warp strands  20 A and weft strands  20 B in woven fabric (as an example). In the illustrative configuration of  FIG. 2 , fabric  22  has a single layer of woven strands  20 . Multi-layer fabric constructions may be used for fabric  22  if desired. Fabric  22  may be woven fabric, knit fabric, or may include strands of material that have been intertwined using other intertwining techniques (e.g., braiding). Sewn strands, felted strands, and other strands may be incorporated into item  10 , if desired. 
     Binder (e.g., polymer) may be incorporated into fabric  22  to bind strands  20  together. Circuitry may be embedded into strands  20  to form a sensor array, a display, and/or other input-output devices  14 . The types of circuit components and materials that are incorporated into fabric  22  may vary across fabric  22 . As a result, different areas of fabric  22  may have different properties. As an example, the properties of area A 1  of fabric  22  may differ from the properties of area A 2  of fabric  22 . 
     Properties of fabric  22  that may be varied throughout fabric  22  (e.g., properties that may differ between areas A 1  and A 2  in the example of  FIG. 2 ) include optical properties such as color, light reflectance, light absorption, and/or light transmission, mechanical properties such as stiffness, moisture repellency, abrasion resistance, etc., electrical properties such as electrical conductivity, input-output capabilities (e.g., display capabilities, acoustic input and output capabilities, sensing capabilities), etc. Properties such as these may be varied by adjusting the amount of binder or other material that is incorporated into fabric  22 , by adjusting the fabric construction (strands per inch, number of fabric layers, weave pattern, knit pattern, etc.) used in forming fabric  22 , and/or adjusting the composition of individual strands  20 . Strands  20  may have properties that vary along their lengths (e.g., stiffness, diameter, optical properties, etc.). 
     Strands  20  may have segments with different properties, as illustrated by segments  30  of strand  20  in  FIG. 3 . For example, a strand may be formed by assembling segments with different embedded circuits and/or other selected properties together. Strand segments may, as an example, be joined using strand segment joining techniques such as thermal joining techniques in which thermoplastic polymer strand material is thermally softened (e.g., melted to a molten state) and then resolidified to form a solid polymer strand segment joint. Conductive lines in strand segments can be joined using ball bonding techniques (e.g., ultrasonic ball bonding techniques, heat-based ball bonding techniques, electric spark-welding-type ball bonding techniques), and/or other suitable electrical connection formation techniques. Computer-controlled strand assembling equipment can be used to assemble custom sequences of strand segments, thereby producing desired circuit networks. Customized strands  20  can be formed by removing desired segments  30  from source strands that are uniform (or nearly uniform) along their lengths and by joining these segments  30  together as shown in  FIG. 3 . With an illustrative configuration, a multi-segment strand may include a series of strand segments containing interconnect lines with interspersed electrical components such as light-emitting diodes, sensors, haptic output devices, control circuits, etc. Each component may be embedded entirely within polymer strand material, thereby insulating the component from its surrounding environment. If desired, embedded electrical components can be formed from bare semiconductor dies (e.g., silicon dies, compound semiconductor dies, or other semiconductor dies without enclosing plastic packages) to conserve space and thereby allow strand diameters to be reduced. 
     Illustrative source strands  20  are shown in the cross-sectional end views of strands  30  of  FIGS. 4, 5, and 6 . 
     In the example of  FIG. 4 , strand  20  includes conductive lines  34  embedded in strand material  32  (e.g., polymer, glass, or other dielectric). Material  32  may be a thermoplastic polymer resin or other suitable dielectric (polymer, glass, etc.). Conductive lines  34  may be formed from metal or other suitable conductive material. There may be one or more lines  34  running along the length of strand  20  (e.g., one or more lines  34 , at least two lines  34 , at least three lines  34 , at least four lines  34 , at least 5 lines  34 , at least 10 lines  34 , fewer than 20 lines  34 , fewer than 8 lines  34 , etc.). 
       FIG. 5  shows how central portion  38  of strand  20  may be different than the outer portion of strand  20 . As an example, the outer portion of strand  20  may be formed from material  32  (e.g., polymer, glass, or other dielectric, and/or other suitable material(s)). Inner portion  38  may be hollow, may be an opening filled with fluid (e.g., water or other liquids), solid material (e.g., polymer), and/or other material. Optional particles  40  may be formed in portion  38  (e.g., portion  38  may contain electrophoretic ink particles, photoluminescent particles, particles or other material for sensing the presence of gases or other materials, and/or other suitable optional structures). 
     As shown in  FIG. 6 , electrical components such as component  42  may be embedded in material  32  of strand  20 . Material  32  may, for example, surround and isolate component  42  from the surrounding environment. Electrical contacts  44  (sometimes referred to as contact pads or terminals) may be formed on component  42 . There may be any suitable number of contacts  44  on component  42  (e.g., at least 1 at least 2, at least 5, at least 20, fewer than 30, fewer than 15, etc.). Contacts  44  can be formed on one side of component  42 , on opposing sides of component  42 , on side portions of component  42 , etc. 
     Component  42  may be an input-output circuit component (e.g., a sensor, a haptic output device, control circuitry, and/or other suitable components (see, e.g., electrical components  16  of  FIG. 1 ). Components  42  may, if desired, be semiconductor dies. The dies may be oriented with their lateral dimensions extending along the length of strand  20  or, as shown in  FIG. 6 , may be oriented so that the surface normal n of the die runs parallel to the Z axis of  FIG. 6  (e.g., surface normal n may extend along the length of strand  20  so that the plane of the die lies perpendicular to the longitudinal axis of strand  20 ). In this illustrative arrangement, component  42  (e.g., a semiconductor die for a light-emitting diode(s), laser(s), integrated circuit, sensor, etc.) may have lateral dimensions (in the X-Y plane of  FIG. 6 ) of at least 1 micron, at least 5 microns, at least 15 microns, at least 50 microns, less than 1000 microns, less than 500 microns, less than 200 microns, less than 100 microns, less than 50 microns, less than 25 microns, less than 15 microns, or other suitable lateral dimension). As an illustrative example, component  42  may be a light-emitting diode die having lateral dimensions of 8 microns and a thickness of less than 4 microns, at least 0.1 microns, or other suitable thickness. 
       FIGS. 7, 8, 9, and 10  are cross-sectional side views of illustrative strands showing how a strand may be formed by joining segments in a desired sequence using computer-controlled segment joining equipment. In the example of  FIGS. 7, 8, 9 and 10 , first segment  30 A, second segment  30 B, and third segment  30 C are being assembled. 
     Initially, a strand (e.g., first strand segment  30 A of  FIG. 7 ) may have a conductive line such as line  34  that is embedded in dielectric strand material  32  (e.g., polymer strand material) without any portion of line  34  exposed. As shown in  FIG. 8 , a portion of the tip of material  32  can be removed (e.g., by application of heat, application of chemicals, or other material removal techniques). This exposes tip portion  34 ′ of conductive path  34 . First segment  30 A and third segment  30 C can be prepared in this way. 
     Assembly equipment for joining segments is shown in  FIG. 9 . As shown in  FIG. 9 , strand segments  30 A and  30 C may be inserted into opposing ends of a guide structure such as tube  50 . Tube  50  may be formed from a non-stick material that is able to withstand high temperatures (e.g., polytetrafluoroethylene). Outer support structures  46  may be used to apply inward pressure (e.g., in directions  52 ) during segment joining operations. Structures  46  may be formed from a tube, from upper and lower dies (e.g., a two-part or other multi-part compression sleeve), and/or other suitable support structures (e.g., clamping structures, vacuum compression structures, pneumatic compression structures, etc.). Optional openings such as opening  48  may be provided to allow compressed gas and/or solvent to be introduced into the interior of tube  50  following segment joining operations (e.g. to use the gas and/or solvent to help release strand  20  from the interior of tube  50 ). 
     Tube  50  may be used to guide desired segments  30  together during segment joining operations. With one illustrative configuration, component  42  is placed within tube  50  between segment  30 A and segment  30 C, as segment  30 A and  30 C are pushed towards each other. Optional heat, ultrasonic vibrations, electricity, etc. may applied to facilitate bonding between lines  34  and component contacts  44 . This causes conductive lines  34  to make electrical connections with respective contacts  44  on component  42  (e.g., via ball bonding). Heat may then be applied (e.g., by heating support structures  46  in the vicinity of component  42 ), which may cause portions of material  32  to melt and flow over component  42 . If desired, polymer that is liquid at room temperature or other coating materials can be used to coat component  42 . The use of heat to melt portions of material  32  to supply coating material for component  42  is illustrative. While conductive lines  34  are pushed into contacts  44 , electrical joints (e.g., mechanical connections and electrical short circuit connections) can be formed between lines  34  and contacts  44 . Any suitable electrical connection formation process may be used (e.g., ball bonding, solder, welds, conductive adhesive, etc.). 
     Following formation of segment  30 B (e.g., by reflowing portions of material  32  over component  42 ), strand  20  may be removed from guide tube  50  and may have the appearance shown in  FIG. 10 . If desired, coating material  32  may be applied over component  44  after left segment  30 A is pushed to the right while right segment  30 C is pushed to the left so that conductive line  34  electrically joins the segments together. In the example of  FIG. 9 , a central segment  30 B is being formed from component  42  and is being joined between segments  30 A and  30 C that contain conductive lines  34 . In general, any suitable number of segments  30  can be joined in tube  50  in each joining operation and each segment may contain any desired circuitry (one or more conductive lines, discrete components such as resistors, inductors, and capacitors, sensors, components formed from semiconductor dies such as light-emitting diodes, lasers, integrated circuits, haptic output devices, other circuits for gathering input and providing output, supercapacitors and other energy storage devices, and/or other suitable circuits. The example of  FIGS. 7, 8, 9, and 10  is illustrative. 
       FIG. 11  is a cross-sectional side view of an illustrative strand  20  formed from three segments ( 30 A,  30 B, and  30 C) showing how strand  20  may have two or more parallel embedded conductive lines  34  (e.g., one or more data lines, positive signal lines, ground lines, power lines, etc.). Conductive lines  34  may be coupled to contacts  44  on opposing sides of component  42  and/or may otherwise be coupled to contacts  44 . 
       FIG. 12  shows another illustrative strand with multiple parallel embedded conductive lines  34 . In the example of  FIG. 12 , strand  20  includes first segment  30 - 1  (e.g., a segment with four conductive lines  34 ), second segment  30 - 2  (e.g., a segment with a metal member or other component  42 - 1  that forms a short circuit between two left-hand lines  34  and thereby couples these two left-hand lines  34  into a single right-hand line  34 ), third segment  30 - 3  (e.g., a segment containing three parallel components  42  such as integrated circuits, light-emitting diodes or lasers, sensors, haptic output devices, etc.), and fourth segment  30 - 4  that contains a component  42  that is coupled between three respective left-hand lines  34  and three respective right-hand lines  34 . In a given strand  20  in fabric  22 , there may be any suitable number of segments  30  and each of these segments may have a potentially different respective embedded circuit. The circuits associated with segments  30  may contain interconnects (e.g., conductive lines  34  including conductive line structures that serve to bridge and/or divide signal paths formed from parallel conductive lines  34 ) and/or semiconductor devices or other embedded components  42 . In fabric  22 , the circuitry of segments  30  in one or more strands  20  may be interconnected. This allows desired circuits (see, e.g., control circuitry  12  and/or input-output devices  14  of  FIG. 1 ) to be formed in fabric  22  and item  10 . External control circuitry and/or other circuitry (batteries, etc.) may be coupled to the circuitry that is embedded in strands  20  for controlling the circuitry in strands  20 , if desired. 
     Strands  20  may have circular cross-sectional shapes or other suitable cross-sectional shapes. To help rotationally align segments  30  during segment joining operations, segments  30  (e.g., strands of material with embedded conductive lines, embedded components, and/or other embedded circuits from which segments  30  are cut or otherwise formed), may be provided with rotational alignment structures. The use of rotational alignment structures may help ensure that conductive lines  34  are joined satisfactorily to desired mating lines  34 , to ensure that each conductive line  34  is joined to a desired contact pad  44  on a component  42 , and to otherwise ensure that the circuitry of adjacent segments  30  is satisfactorily interconnected. 
     In the example of  FIG. 13 , notch  54  in the outer surface of segment  30  forms a rotational alignment feature. In the example of  FIG. 14 , planar portion  56  of segment  30  forms a rotational alignment feature.  FIG. 15  shows how alignment structures for strand segment  30  may be formed using planar surface  56  and notch  54 .  FIG. 16  is an exploded perspective view of a pair of segments  30  showing how the tips of segments  30  may be provided with structures such as alignment protrusions  58  and mating alignment recesses  60  to facilitate rotational alignment when joining segments  30 . Other types of alignment structures may be provided on the side surfaces and/or end surfaces of segments  30  to help ensure that segments  30  that are being joined to each other are rotationally aligned with each other. The examples of  FIGS. 13, 14, 15, and 16  are illustrative. 
     If desired, strands  20  may be provided with portions that join a single strand segment to multiple strand segments, thereby dividing and/or joining strands  20 . As shown in  FIG. 17 , for example, a single strand (strand segment)  30 L can be joined to three respective strands (strand segments)  30 R 1 ,  30 R 2 , and  30 R 3 . In this way, strands  20  can split into sets of multiple respective strands  20  and/or multiple strands  20  can be combined into a single corresponding strand  20 . This approach may be used to divide and combine strand segments formed from hollow tubing, strand segments formed from various components  42 , strands containing lines  34  that form interconnects, and/or other strands. In the example of  FIG. 17 , strand  30 L contains three parallel conductive lines  34  embedded in insulating material  32  (e.g., polymer) and strands  30 R 1 ,  30 R 2 , and  30 R 3  each contain a corresponding one of three associated conductive lines  34 . Signal paths may be joined and divided in this way to facilitate signal routing, to form a wiring harness (e.g., by dividing signal paths into individual strands for soldering to respective contact pads, etc.), or to form other structures with joined and/or divided signal paths. 
     In some segment joining operations, supplemental structures such as support rings may be formed around the seam between joined segments. For example, a polymer reinforcement collar may be attached around a seam using adhesive, melting and reflowing of thermoplastic material, and/or other attachment techniques. Joints (splices) between segments may be formed using spliced surfaces that run perpendicular to the longitudinal axes of the strands or may be formed using spliced surfaces that are angled (e.g., at 30°) relative to the longitudinal axes of the strands. 
     Strands  20  may, if desired, be formed using techniques such as melt spinning, wet and dry spinning, electro-spinning, and/or thermal drawing. An illustrative melt spinning arrangement that may be used in forming a strand is shown in  FIG. 18 . As shown in  FIG. 18 , melt spinning tool  70  may be used to form strand  20  from source materials  80  and  82  (e.g., at least two source materials, at least 3 source materials, at least 5 source materials, at least 10 source materials, fewer than 20 source materials, etc.). Die plate stack  72  includes multiple die plates  78 . There may be, for example, at least 10, at least 40, at least 100, at least 200, fewer than 250, fewer than 120, or fewer than 50 die plates  78  in stack  72 . Each die plate  78  may be formed from a support structure such as a metal layer  74  with a desired set of openings  76 . The patterns of openings  76  in plates  78  of stack  72  can be selected to manipulate incoming materials sources (see, e.g., sources  80  and  82 ) and thereby form a strand  20  with a desired pattern of the material from sources  80  and  82  as strand  20  is extruded through stack  72  and drawn in direction  84  from tool  70 . 
     The input materials to strand  20  (e.g., the materials of sources  80  and  82 ) may be insulating materials (e.g., dielectric materials such as polymer, glass, ceramic, etc.), conductive materials (e.g., polymer filled with metal particles or other conductive material, etc.), may be semiconductors, photoluminescent materials, and/or materials with other desired properties for forming embedded circuitry. In some configurations, electrical components  20  can be formed within a strand as it is being formed. In other configurations, electrical components may be joined with other circuits using a tube-based arrangement of the type described in connection with  FIG. 9  (as an example). 
     After forming strands such as strand  20  of  FIG. 18  and/or other strands with desired patterns of embedded interconnects, embedded semiconductor dies, other electrical components  16 , and/or other embedded circuits, optical components such as waveguides, etc., these strands  20  (which may be axially uniform) can be divided to form respective segments  30  and, using computer-controlled strand segment assembly equipment (see, e.g., the illustrative equipment of  FIG. 9 ) can be joined together to form an assembled strand  20  with a desired pattern of interconnected strand segments  30  (e.g., a strand that is not uniform along its length). 
     Illustrative equipment  90  for forming items  10  of system  8  is shown in  FIG. 19 . As shown in  FIG. 19 , equipment  90  may include strand formation tools such as equipment  92  for forming strands of material with embedded circuitry that are to be used as source strands for segments  30 . Equipment  92  may form strands  20  or parts of strands  20  using melt spinning, wet and dry spinning, electro-spinning, thermal drawing, etc. Circuitry can be embedded within one or more strand materials  32 , so that strands  20  are uniform or nearly uniform along their lengths. For example, a strand  20  may be formed that contains a continuous set of embedded components each of the same type of component (e.g., a series of light-emitting diodes or a series of integrated circuits). These components may, for example, be provided at fixed distances along the length of a strand. The linear density of components  42  along the length of strand  20  may be, for example, at least 1/mm, at least 10/mm, at least 100/mm, at least 1000/mm, less than 500/mm, less than at 150/mm, less than 25/mm, etc. In other configurations, axially uniform sensor electrodes and/or other axially uniform structures may be formed in a source strand. 
     It may be relatively efficient to form source strands with large numbers of embedded components using a process that produces strands that are uniform along their lengths. Equipment  92  may form any suitable number of source strands (e.g., at least 5, at least 10, at least 100, at least 250, fewer than 125, fewer than 50, etc.). Each of the source strands (e.g., each of the axially uniform or semi-uniform strands produced by equipment  92 ) may be available to other equipment such as segment formation and joining equipment  96  for use in assembling strands with desired patterns of embedded circuits. With one illustrative arrangement, a rotating turret may be used to present each of numerous different source strands to a computer-controlled strand segment assembling head, which selects segments from among each of the available source strands. 
     Equipment  96  may, for example, remove segments  30  of desired lengths from desired source strands and may then join these selected segments  30  together in a desired pattern to form an assembled strand  20  with a desired network of embedded circuitry. Equipment  96  may serve as a computer-controlled pick-and-place tool that picks desired strand segments from a set of strand sources and that places these strand segments end-to-end in a desired combined strand  20 . Strands  20  with customized sets of strand segments and, if desired, axially uniform strands may be used in forming item  10 . 
     After forming uniform strands and strands with desired customized patterns of embedded circuits, for example, strand intertwining equipment  94  (e.g., equipment for weaving, knitting, braiding, sewing, etc.) can be used for forming fabric  22  from these strands. Equipment  98  may be used to form item(s)  10  using fabric  22  and structures formed from other materials. 
     The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20180918
Publication Date: 20220125
Grant Date: 20220125
Priority Date: 20180319
Inventors: KEATING, STEVEN J.
SUNSHINE, Daniel D.
GRENA, BENJAMIN J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H10H20/857", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/292", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/292", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/533", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2401/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L23/5387", "inventive": true, "first": true, "tree": "[]"}, {"code": "D10B2101/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "D02G3/441", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L23/5389", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L23/5386", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D1/0088", "inventive": true, "first": true, "tree": "[]"}, {"code": "D03D1/0088", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/167", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2401/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "D10B2401/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L25/0655", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2101/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "D02G3/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/0753", "inventive": true, "first": false, "tree": "[]"}, {"code": "D02G3/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/25", "inventive": true, "first": false, "tree": "[]"}, {"code": "D02G3/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/47", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L23/5389", "inventive": true, "first": false, "tree": "[]"}, {"code": "D02G3/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/0753", "inventive": true, "first": false, "tree": "[]"}, {"code": "D02G3/441", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2101/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "D03D1/0088", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L23/5387", "inventive": true, "first": true, "tree": "[]"}, {"code": "D10B2401/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "D10B2401/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L25/0655", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L23/5386", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L33/62", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L25/167", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 67903656