U.S. patent application number 15/877378 was filed with the patent office on 2019-12-12 for flexible fabric ribbon connectors for garments with sensors and electronics.
The applicant listed for this patent is Andrea ALIVERTI, Gianluigi LONGINOTTI-BUITONI, Fabrizio PALLAI. Invention is credited to Andrea ALIVERTI, Gianluigi LONGINOTTI-BUITONI, Fabrizio PALLAI.
Application Number | 20190373963 15/877378 |
Document ID | / |
Family ID | 56920877 |
Filed Date | 2019-12-12 |
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United States Patent
Application |
20190373963 |
Kind Code |
A9 |
LONGINOTTI-BUITONI; Gianluigi ;
et al. |
December 12, 2019 |
FLEXIBLE FABRIC RIBBON CONNECTORS FOR GARMENTS WITH SENSORS AND
ELECTRONICS
Abstract
Elastic electrical connectors that may be incorporated into a
garment to connect multiple electrical components in the garment.
These electrical connectors are typically long strips of fabric
substrate to which wires are attached along a length of one side in
a sinusoidal or zig-zag pattern. The connector may also include an
adhesive coating on one side to secure it to a fabric. The wires
are electrically insulated, which may be a thermoremoable
insulation (e.g., a polyurethane having a melting point of
<400.degree. C.). The wires may be attached to the surface of
the fabric strip by a stitch at each peak and trough of the
sinusoidal or zig-zag pattern with a length between peak and trough
stitches between about 1 mm and 15 mm.
Inventors: |
LONGINOTTI-BUITONI; Gianluigi;
(Haute-Nendaz, CH) ; ALIVERTI; Andrea; (Como,
IT) ; PALLAI; Fabrizio; (Luxembourg, LU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LONGINOTTI-BUITONI; Gianluigi
ALIVERTI; Andrea
PALLAI; Fabrizio |
Haute-Nendaz
Como
Luxembourg |
|
CH
IT
LU |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20180199635 A1 |
July 19, 2018 |
|
|
Family ID: |
56920877 |
Appl. No.: |
15/877378 |
Filed: |
January 22, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/IB2016/001146 |
Jul 20, 2016 |
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15877378 |
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15813073 |
Nov 14, 2017 |
10045439 |
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PCT/IB2016/001146 |
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15324152 |
Jan 5, 2017 |
9817440 |
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PCT/IB2015/001802 |
Jul 14, 2015 |
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15813073 |
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14331185 |
Jul 14, 2014 |
8945328 |
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15324152 |
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14023830 |
Sep 11, 2013 |
9282893 |
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14331185 |
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14612060 |
Feb 2, 2015 |
9986771 |
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PCT/IB2015/001802 |
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14331185 |
Jul 14, 2014 |
8945328 |
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14612060 |
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62194731 |
Jul 20, 2015 |
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61699440 |
Sep 11, 2012 |
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61862936 |
Aug 6, 2013 |
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61950782 |
Mar 10, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 33/92 20130101;
A61B 5/04004 20130101; A41B 1/08 20130101; A61B 5/0205 20130101;
A42B 1/046 20130101; A61B 5/0402 20130101; A61B 2562/222 20130101;
A61B 5/4806 20130101; A41D 1/005 20130101; A61B 5/6804
20130101 |
International
Class: |
A41D 1/00 20060101
A41D001/00; A42B 1/04 20060101 A42B001/04; A41B 1/08 20060101
A41B001/08; A61B 5/00 20060101 A61B005/00; H01R 33/92 20060101
H01R033/92 |
Claims
1. An elastic electrical connector device for incorporating into a
garment to connect multiple electrical components in the garment,
the device comprising: an elongate strip of fabric substrate having
a first side and a second side; a plurality of wires extending
along a length of the first side of the elongate strip of fabric
substrate in a sinusoidal or zig-zag pattern, wherein each of the
wires is electrically insulated, and wherein the plurality of wires
are attached to the first surface by a stitch with a thread through
the elongate strip of fabric substrate at a plurality of peaks and
troughs of the sinusoidal or zig-zag pattern; and an adhesive
coating the first side.
2. The device of claim 1, wherein the elastic electrical connector
device has a maximum thickness of less than about 2 mm.
3. The device of claim 1, wherein the plurality of wires comprises
a bundle of wires twisted together.
4. The device of claim 1, wherein each of the wires is individually
coded along its outer length.
5. The device of claim 1, wherein each of the plurality of wires is
electrically insulated with a thermoremovable insulator.
6. The device of claim 1, wherein each of the wires comprises a
copper wire electrically insulated with a polyurethane
material.
7. The device of claim 1, wherein the sinusoid or zig-zag pattern
has an amplitude from about 0.5 mm to 15 mm.
8. The device of claim 1, wherein a length between peak and trough
stitches is between about 1 mm and 15 mm.
9. The device of claim 1, wherein the adhesive coating comprises a
hot melt film having a low melting point.
10. The device of claim 1, wherein the adhesive coating has a
thickness of between 10 and 200 micrometers thick.
11. The device of claim 1, wherein the adhesive coating comprises a
hot melt film having a melting point of between about 130.degree.
C. and 200.degree. C.
12. The device of claim 1, wherein the plurality of wires comprises
between 2 and 10 wires.
13. The device of claim 1, wherein the elongate strip of fabric
substrate comprises a stretchable fabric substrate.
14. The device of claim 1, wherein the elongate strip of fabric
substrate comprises a polyamide/elastane blend fabric.
15. The device of claim 1, wherein the elongate strip of fabric
substrate is between about 0.6 mm and about 3 cm wide and greater
than about 10 cm long.
16. The device of claim 1, further comprises a removable backing on
the first side covering the adhesive.
17. The device of claim 1, further comprises a removable paper
backing on the first side covering the adhesive.
18. The device of claim 1, wherein the bundle of wires may slide
relative to the elongate strip of fabric substrate within the
stitch of thread at the plurality of peaks and troughs.
19. An elastic electrical connector device for incorporating into a
garment to connect multiple electrical components in the garment,
the device comprising: an elongate strip of fabric substrate having
a first side with a length; a bundle of wires that are twisted
together extending along the length of the first side of the
elongate strip of fabric substrate in a sinusoidal or zig-zag
pattern, wherein each of the wires is electrically insulated with a
thermoremovable insulator, and wherein the bundle of wires are
attached to the first surface by a stitch with a thread material
through the elongate strip at each peak and trough of the
sinusoidal or zig-zag pattern, wherein the length between peak and
trough stitches is between about 1 mm and 15 mm; and an adhesive
coating the first side.
20. A method of forming an elastic electrical connector that may be
applied to a garment to connect multiple electrical components of
the garment, the method comprising: attaching an elongate bundle of
wires to a first surface of an elongate strip of fabric in a
sinusoidal or zig-zag pattern comprising alternating peaks and
troughs, wherein the wires are each electrically insulated, and
wherein the bundle is attached to the first surface by at least one
stitch at each peak and trough of the sinusoidal or zig-zag
pattern, wherein the length between peak and trough stitches is
between about 1 mm and 15 mm; applying an adhesive coating the
first side; and covering the adhesive coating with a removable
backing.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority as a continuation-in-part
of International Patent Application No. PCT/IB2016/001146, filed on
Jul. 20, 2016, and titled "FLEXIBLE FABRIC RIBBON CONNECTORS FOR
GARMENTS WITH SENSORS AND ELECTRONICS," which claims priority to
U.S. Provisional Patent Application No. 62/194,731, titled
"FLEXIBLE FABRIC RIBBON CONNECTORS FOR GARMENTS WITH SENSORS AND
ELECTRONICS," and filed on Jul. 20, 2015.
[0002] This application may be related to U.S. patent application
Ser. No. 14/612,060, filed on Feb. 2, 2015 ("GARMENTS HAVING
STRETCHABLE AND CONDUCTIVE INK"), which is a continuation of U.S.
patent application Ser. No. 14/331,142 filed Jul. 14, 2014
("COMPRESSION GARMENTS HAVING STRETCHABLE AND CONDUCTIVE INK").
This application may also be related to U.S. patent application
Ser. No. 14/644,180, filed Mar. 10, 2015 ("PHYSIOLOGICAL MONITORING
GARMENTS"), which claims priority to U.S. Provisional Patent
Application No. 62/097,560, filed on Dec. 29, 2015 ("STRETCHABLE,
CONDUCTIVE TRACES AND METHODS OF MAKING AND USING SAME").
INCORPORATION BY REFERENCE
[0003] All publications and patent applications mentioned in this
specification are herein incorporated by reference in their
entirety to the same extent as if each individual publication or
patent application was specifically and individually indicated to
be incorporated by reference.
FIELD
[0004] The disclosure herein relates to electrical connectors for
garments having multiple integrated electrical components
(including sensors), and garments including them. In particular,
this disclosure relates to strips of elastic electrical connectors
that may be used to connect multiple electrical devices on a
garment having integrated electrical devices.
BACKGROUND
[0005] In recent years the development of wearable electronics has
dramatically expanded. Computers with ever-faster computer
processors enabled faster communication with increased processing
speed and improved analysis of vast quantities of data. In
addition, sensor technology has also rapidly expanded how patients
have been monitored, even by non-professionals. The development of
various sensors enabled a variety of measurements to be taken and
analyzed by a computer to generate useful information. The use of
medical sensing technology in combination with various
communications platforms may provide new and interesting ways for
people, including patients, to be monitored or to monitor
themselves and communicate the results of the monitoring with their
physician or caregiver.
[0006] Cardiovascular and other health-related problems, including
respiratory problems may be detected by monitoring a patient.
Monitoring may allow early and effective intervention, and medical
assistance may be obtained based on monitored physiological
characteristics before a particular health issue becomes fatal.
Unfortunately, most currently available cardiovascular and other
types of health monitoring systems are cumbersome and inconvenient
(e.g., impractical for everyday use) and in particular, are
difficult or impractical to use for long-term monitoring,
particularly in an unobtrusive manner.
[0007] Clothing that includes sensors have been previously
suggested. See, e.g., US2007/0178716 to Glaser et al., which
describes a "modular microelectronic-system" designed for use with
wearable electronics. US2012/0071039 to Debock et al. describes
interconnect and termination methodology fore-textiles that include
a "conductive layer that includes conductors includes a terminal
and a base separately provided from the terminal. The terminal has
a mating end and a mounting end." US2005/0029680 to Jung et al.
describes a method and apparatus for the integration of electronics
in textiles. These wearable electronic garments are limited
however, in their ability to comfortably and accurately link
electronics (including sensors) on the garment.
[0008] It has been proposed that patient health parameters,
including vital signs (such as ECG, respiration, blood oxygenation,
heart rate, etc.) could be actively monitoring using one or more
wearable monitors, however, to date such monitors have proven
difficult to use and relatively inaccurate. Ideally such monitors
could be unobtrusively worn by the subject (e.g., as part of a
garment, jewelry, or the like). To date, the wearable electronics
garments proposed all suffer from a number of deficits, including
being uncomfortable, difficult to use and manufacture, and
providing inaccurate results. For example, in applications such as
US 2012/0136231, a number of individual electrodes are positioned
on the garment and connected to a processor by woven conductive
fibers or the like; although such garments "require . . .
consistent and firm conductive contact with the subject's skin," in
order to provide accurate readings, such designs require that the
garment be restrictive in order to prevent movement of the garment
(and thus sensors) contacting these skin regions. Such a
configuration rapidly becomes uncomfortable, particularly in a
garment that would ideally be worn for many hours or even days. In
addition, even such tightly worn garments often move relative to
the wearer (e.g., slip or ride up). Further, devices/garments such
as those described in the prior art are difficult and expensive to
manufacture, and are often rather "fragile", preventing robust
usage and washing. Finally, such devices/garments typically do not
allow processing of manual user input directly on the garment, but
either relay entirely on passive monitoring, or require an
interface of some sort (including off-garment interfaces).
[0009] The use of garments including one or more sensors that may
sense biometric data have not found widespread use. In part, this
may be because such garments may be limited in the kinds and
versatility of the inputs that they accept, as well as limits in
the comfort, and form factor of the garment. For example, sensors,
and the leads providing power to and receiving signals from the
sensors have not been fully integrated with the garment in a way
that allows the garment to be flexible, attractive, practical, and
above all, comfortable. For example, most such proposed garments
have not been sufficiently stretchable. Finally, such proposed
garments are also limited in the kind of data that they can
receive, and how they process the received information.
[0010] What is needed are apparatuses (including garments) having
multiple sensors that may be comfortably worn, yet provide
relatively accurate and movement-insensitive measurements over a
sustained period of time. It would also be beneficial to provide
garments that can be easily and inexpensively manufactured.
[0011] In particular, what is needed are stretchable and conductive
connectors that can be attached or applied onto a garment. These
stretchable, conductive connectors may be used even with the most
stretchable of fabrics, and/or with compression fabrics/compression
garments, and moved through numerous stretch/relaxation cycles with
the underlying fabric without breaking and while maintaining a
stable electrical connection over time and use. The apparatuses,
including devices and systems including them described herein may
address some or all of the problems identified above.
SUMMARY OF THE DISCLOSURE
[0012] Described herein garments including integrated electronic
sensors and methods of making and using them. In particular, the
methods and apparatuses described herein may provide methods and
apparatuses (systems, devices, etc.) for forming garments with
wearable electronics that may be fabricated in a robust, efficient,
and cost-effective manner. For example, described herein are strips
of elastic electrical connectors that may be used to connect
multiple electrical devices on a garment having integrated
electrical devices (including sensors). These strips of elastic
electrical connectors may be adhesively applied to a garment (or a
fabric to forma garment) and may be comfortably worn while
providing robust electrical connection.
[0013] For example, described herein are elastic electrical
connector devices for incorporating into a garment to connect
multiple electrical components in the garment. Such devices may
include: an elongate strip of fabric substrate having a first side
and a second side; a plurality of wires extending along a length of
the first side of the elongate strip of fabric substrate in a
sinusoidal or zig-zag pattern, wherein each of the wires is
electrically insulated, and wherein the plurality of wires are
attached to the first surface by a stitch at a peak and a trough of
the sinusoidal or zig-zag pattern; and an adhesive coating the
first side.
[0014] As used herein, a sinusoidal pattern is a curve that
describes a repeating (or oscillating) pattern, and may broadly
include zig-zag, saw-tooth, (e.g., triangular), smooth, or other
repeating waves having a peak and a trough, where the peak and
trough are connected by non-vertical paths (e.g., excluding purely
square waveforms). Thus, in general the oscillating pattern of the
wires in any of the apparatuses (e.g., devices, garments, etc.)
described herein may be referred to as an oscillating pattern
having a series of longitudinally repeating peaks and troughs,
wherein each peak is followed by an adjacent trough and separated
by a longitudinal distance (e.g., greater than 0.1 mm, 0.5 mm, 1
mm, etc.) and separated by a vertical distance (e.g.,
amplitude).
[0015] Any of these elastic electrical connector device for
incorporating into a garment to connect multiple electrical
components in the garment may include: an elongate strip of fabric
substrate having a first side with a length; a bundle of wires that
are twisted together extending along the length of the first side
of the elongate strip of fabric substrate in a sinusoidal or
zig-zag pattern, wherein each of the wires is electrically
insulated with a thermoremovable insulator, and wherein the bundle
of wires are attached to the first surface by a stitch at each peak
and trough of the sinusoidal or zig-zag pattern wherein the length
between peak and trough stitches is between about 1 mm and 15 mm;
and an adhesive coating the first side.
[0016] The elastic electrical connector may be a generally thin
strip (e.g., ribbon, band, etc.) that may be relatively thin and
narrow. For example, the strip may have a maximum thickness of less
than about 2 mm (e.g., less than about 1.9 mm, less than about 1.8
mm, less than about 1.7 mm, less than about 1.6 mm, less than about
1.5 mm, less than about 1.4 mm, less than about 1.3 mm, less than
about 1.2 mm, less than about 1.1 mm, less than about 1.0 mm,
etc.).
[0017] The elastic electrical connector may be any appropriate
length and thickness. For example, the elastic electrical connector
(the elongate strip of fabric substrate of the elastic electrical
connector) may be between about 0.6 mm and about 3 cm wide, and
greater than about 10 cm long. The length may extend for meters,
including greater than 1 m, greater than 2 m, greater than 3 m,
etc. the elastic electrical connector may be spooled up so that it
may be cut to fit and conveniently used in a variety of
fabrications.
[0018] The plurality of wires comprises a bundle of wires twisted
together. In some variations, the plurality may be wires arranged
in parallel. The plurality of wires generally includes between 2
and 20 (e.g., between 2 and 18, 2 and 17, 2 and 16, 2 and 15, 2 and
14, 2 and 13, 2 and 12, 2 and 11, 2 and 10, 2 and 9, 2 and 8, 2,
etc.). In general, each of the wires is individually coded along
its outer length, so that it may be distinguished from the other
wires. For example, each wire may be a distinct color and/or
pattern (e.g., printed on the outer visible surface of the wire.
When the plurality is a bundle of wires, the wires are typically
individually electrically insulated. Thus, the bundle is not
encased or enclosed as a group, so that they can be individually
separated out from the bundle, though pulled out of the stitch or
attachment holding them to the substrate fabric.
[0019] As mentioned, each wire is typically individually
electrically insulated, and this electrical insulation may be
configured as a thermoremovable insulator that can be removed by
application of a relatively low heat, as applied during soldering.
Thus, the wires may not need to be separately stripped or removed
of the insulation. For example, the wires may be made of a copper
wire that is electrically insulated with a polyurethane.
[0020] The wires are typically attached on one side of the
substrate (fabric) in a sinusoidal pattern, or more specifically a
zig-zag pattern. For example, the sinusoid or zig-zag pattern may
have an amplitude (from peak to trough, measured in a direction
normal to the zig-zag pattern) that is from about 0.2 mm to 20 mm
(e.g., from 0.5 mm to about 15 mm, etc.). The distance between the
peak and trough measured along the sinusoidal (e.g., zig-zag)
pattern, e.g., a length between peak and trough stitches, may be
between about 0.5 mm and about 20 mm (e.g., between about 1 mm and
15 mm, etc.).
[0021] The elastic electrical connector typically has a relaxed
configuration (e.g., unstretched) and a stretched configuration.
The garment may be stretched up to about 100% (2.times.) or more
(e.g., 200%, 300%, etc.) of its relaxed configuration without
breaking one of the connecting wires.
[0022] In some variations, it is helpful that the wires (e.g.,
bundle of wires) are held to the garment by one or more stitches at
the peak and trough of the sinusoidal pattern, as through stitches
around the wires that pass through the substrate. This
configuration may allow the stitches to act as eyelets that the
wires may slide, while still maintaining the shape of the
sinusoid.
[0023] In any of the elastic electrical connectors described herein
the adhesive coating may be a relatively thin adhesive coating. For
example, the adhesive coating may comprise a hot melt film having a
low melting point. The adhesive coating may have a thickness of
between 10 and 200 micrometers thick (e.g., 20 and 190, 30 and 180,
40 and 170, 50 and 160, 60 and 150, etc., or any thickness between
10 and 200 micrometers. The actual thickness may depend on the
material, though thinner coatings are preferred. The adhesive is
configured to secure the elastic electrical connector to the
garment that it will form a part of. Thus, any appropriate
garment-compatible (and somewhat elastic and/or flexible) adhesive
may be used. For example, the adhesive coating comprises a hot melt
film having a melting point of between about 130.degree. C. and
200.degree. C.
[0024] In any of these variations, the substrate fabric may be
formed of the same fabric as the garment to which the elongate
strip of fabric substrate is to be attached, including a
stretchable fabric substrate. For example, the elongate strip of
fabric substrate may comprise a polyamide/elastane blend fabric
(e.g., 74% polyamide, 26% elastane).
[0025] Any of these devices (elastic electrical connectors) may
include a removable backing on the first side covering the
adhesive. The back may be paper (e.g., waxed paper), plastic, or
the like, and may be peeled off to expose the adhesive.
[0026] Also described herein are elastic electrical connector
device for incorporating into a garment to connect multiple
electrical components in the garment, the device comprising: an
elongate strip of fabric substrate having a first side and a second
side; a plurality of wires extending along a length of the first
side of the elongate strip of fabric substrate in a sinusoidal or
zig-zag pattern, wherein each of the wires is electrically
insulated, and wherein the plurality of wires are attached to the
first surface; and an adhesive coating the first side.
[0027] Method of making these elastic electrical connectors are
also described herein. A method of forming an elastic electrical
connector that may be applied to a garment to connect multiple
electrical components of the garment may include: attaching an
elongate bundle of wires to a first surface of an elongate strip of
fabric in a sinusoidal or zig-zag pattern comprising alternating
peaks and troughs, wherein the wires are each electrically
insulated, and wherein the bundle is attached to the first surface
by at least one stitch at each peak and trough of the sinusoidal or
zig-zag pattern, wherein the length between peak and trough
stitches is between about 1 mm and 15 mm; applying an adhesive
coating the first side; and covering the adhesive coating with a
removable backing.
[0028] Also described herein are garments made using the elastic
electrical connectors described herein. For example, a garment may
include: a first fabric; a plurality of electrical components on
the first fabric; and at least one elastic electrical connector
comprising: an elongate strip of a second fabric substrate having a
first side; a plurality of wires extending along a length of the
first side of the elongate strip of fabric substrate in a
sinusoidal or zig-zag pattern, wherein each of the wires is
electrically insulated, and wherein the plurality of wires are
attached to the first surface by a stitch at a peak and a trough of
the sinusoidal or zig-zag pattern, and an adhesive coating the
first side; wherein the each electrical component is connected to
one or more wire in the at least one electrical connector. In
general, the electrical components described herein that may be
connected by the elastic electrical connectors may include any
appropriate electrical component, and in particular (but not
limited to) a sensor.
[0029] A method of forming a garment may include: adhesively
attaching one or more elastic electrical connector to a first
fabric, each elastic electrical connector comprising: an elongate
strip of a second fabric substrate having a first side; a plurality
of wires extending along a length of the first side of the elongate
strip of fabric substrate in a sinusoidal or zig-zag pattern,
wherein each of the wires is electrically insulated, and wherein
the plurality of wires are attached to the first surface by a
stitch at a peak and a trough of the sinusoidal or zig-zag pattern,
and an adhesive coating the first side; and attaching a plurality
of electrical components to the first fabric, wherein each
electrical component is connected to at least one wire of the one
or more elastic electrical connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The novel features of the invention are set forth with
particularity in the claims that follow. A better understanding of
the features and advantages of the present invention will be
obtained by reference to the following detailed description that
sets forth illustrative embodiments, in which the principles of the
invention are utilized, and the accompanying drawings of which:
[0031] FIG. 1A is a schematic illustration of an elastic electrical
connector device for incorporating into a garment to connect
multiple electrical components in the garment, shown in a top view.
FIG. 1B is a side view of the electrical connector shown in FIG.
1A.
[0032] FIG. 2 illustrates a roll of elastic electrical connector
such as the connector shown in FIG. 1A.
[0033] FIG. 3 is a schematic illustration of another example of an
elastic electrical connector for use in connecting multiple
electrical components to a garment.
[0034] FIG. 4 shows one example of a bundle of insulated (enameled)
wires of an elastic electrical connector connected on one side of a
fabric material forming an elastic electrical connector.
[0035] FIG. 5 is another example of a bundle of insulated
(enameled) wires of an elastic electrical connector connected on
one side of a fabric material forming an elastic electrical
connector.
[0036] FIG. 6 illustrates the use an elastic electrical connector
such as those described herein to electrically connect with an
electrical component (e.g., a printed circuit board, or PCB, of a
UART BUS).
[0037] FIG. 7 illustrates the use an elastic electrical connector
such as those described herein to electrically connect with another
electrical component (e.g., an external connector).
[0038] FIG. 8 illustrates the use an elastic electrical connector
such as those described herein to electrically connect with an
electrical component (e.g., a strain gauge).
[0039] FIG. 9 illustrates the use an elastic electrical connector
such as those described herein to electrically connect with an
electrical component (e.g., electrodes).
[0040] FIGS. 10A-10C illustrate data characterizing the electrical
properties and behavior of one example of an elastic electrical
connector as described herein. FIG. 10A is a graph showing test
results illustrating the voltage through wires of a flexible
(fabric) connector having four wires, over repeated cycles of
stretching (up to 3000 cycles). FIG. 10B graphically illustrates an
example of a connector having six wires. FIG. 10C illustrates an
example of a connector having 8 connectors.
[0041] FIG. 11 is a schematic section through a bundle of six
insulated (enameled) wires that may be used to form an elastic
electrical connector.
[0042] FIG. 12 is a schematic section through a bundle of four
insulated (enameled) wires that may be used to form an elastic
electrical connector.
[0043] FIG. 13 illustrates on elongate strip of fabric configured
as an elastic electrical connector.
[0044] FIG. 14 shows an enlarged view of the proximal end of the
elastic electrical connector device of FIG. 13, showing the ends of
six insulated wires forming the wire bundle arranged in a zig-zag
pattern along the length of the elastic electrical connector.
[0045] FIG. 15A is an enlarged view of a stretch sensor such as the
one shown in FIG. 8, electrically connected to two of the wires of
an elastic electrical connector.
[0046] FIG. 15B shows another view (enlarged) of a region of a
stretch sensor similar to the one shown in FIG. 15A with the inside
exposed; FIG. 15C shows the sensor of FIG. 15B with a cover
attached.
[0047] FIG. 16 is an example of an elastic electrical connector
shown connected to multiple electrical components, including a body
ground pad, ECG electrode, and breath sensor. Additional electrical
components may also be added.
[0048] FIGS. 17A-17F illustrate assembly of an electrode sensor.
These figures are showing the new electrode assembly (in this case
is the EMG electrode). Take note that this new structure is common
to all of our electrodes and basically it is made applying, by
thermal process, the ink sensor on a fabric base (not elastic) with
glue film (the same of the ribbon) on the other side. This
"multilayer" gets holed, then the rivet is inserted in the
hole.
[0049] FIG. 18 illustrates machining of an electrode sensor by
riveting a connector in contact with a conductive ink forming the
sensor.
[0050] FIGS. 19A and 19B show an EMG electrode. FIG. 19A shows the
front (wearer-facing) surface, while FIG. 19B shows the back
surface that will be attached to the garment. The sensor may be
connected to a connector (e.g., a SPIDON as described herein) and
then applied to the garment.
[0051] FIG. 20 illustrates soldering of an EMG electrode such as
the ones shown in FIGS. 19A and 19B to an electrical connector
device by connecting (soldering) at the cap of the attached
rivet.
[0052] FIG. 21 shows one example of a sensor management system
(SMS), including a housing, connected to a fabric (e.g., garment),
to which an elastic electrical connector may also be connected.
[0053] FIG. 22 illustrates an assembled SMS connector and housing
attached to a fabric (garment).
[0054] FIG. 23 shows a top of an SMS housing.
[0055] FIG. 24 shows a bottom of an SMS housing.
[0056] FIG. 25 shows another view of a top of an SMS housing
including an epoxy resin for waterproofing.
[0057] FIG. 26 illustrates different housing configurations (e.g.,
left 20 poles, middle 24 poles, and right 28 poles) for an SMS
housing.
[0058] FIG. 27A illustrates a multimedia module device (MMM device)
mating with an SMS connector, show in partial cross-section. FIG.
27B shows the MMM device and SMS connector fully mated.
[0059] FIG. 28 shows a solder layer of an SMS microcontroller.
[0060] FIG. 29 shows a component layer of an SMS
microcontroller.
[0061] FIG. 30A shows the SMS microcontroller of FIGS. 28 and 29
housed within an SMS housing.
[0062] FIG. 30B shows another example of a housing for an SMS
microcontroller.
[0063] FIG. 31 is another illustration, similar to that shown in
FIG. 6, of an SMS connected to an elastic electrical connector as
described herein.
[0064] FIG. 32 illustrates another example of electrodes connected
to an elastic electrical connector, similar to that shown in FIG.
9.
[0065] FIG. 33 illustrates an elastic electrical connector
connected to a six-pole female connector and a splitter PCB.
[0066] FIG. 34 shows four elastic electrical connectors, each
electrically connected to the SMS connector.
[0067] FIG. 35A illustrates a system or subsystem (referred to
herein as a `spydon system` or spydon subsystem) including multiple
(e.g., 5) elastic electrical connectors that each contain a
plurality of conductive wires connected or connectable distally to
multiple different electrical components (e.g., sensors) and
connected at a proximal end to an SMS connector; this entire
network may be adhesively and/or otherwise transferred and
connected to a fabric to form a wearable garment.
[0068] FIG. 35B is another example of a system (or subsystem)
having multiple elastic electrical connectors each containing a
plurality of conductive wires connected or connectable to multiple
different electrical components (e.g., sensors) and connected at a
proximal end to an SMS connector, similar to that shown in FIG.
35A.
[0069] FIGS. 36-39 illustrate an alternative variation of an SMS
(FIG. 38) and housing (FIGS. 36, 37 and 39) for the SMS
circuitry.
[0070] FIGS. 40A-40C illustrate examples of conductive thread sewn
into a substrate (e.g., fabric); FIG. 31A shows different patterns
of stitches, having different pitches and widths (angles); FIG. 40B
shows an example of five parallel conductive threads that may
connect to five different sensors. FIG. 40C shows an example of a
single conductive thread (wire).
[0071] FIG. 41 illustrates one example of a wired ribbon (an
elastic electrical connector) that may be used to connect a
stretchable fabric.
[0072] FIG. 42 illustrates the attachment of a conductive elastic
ribbon formed as shown in above, to a stretch sensor using two
wires from the elastic electrical connector.
[0073] FIGS. 43, 44 and 45 illustrate one method of making a sealed
conductive ribbon (elastic electrical connector) including a
stretch sensor coupled to an elastic electrical connector.
[0074] FIGS. 46-48 show examples of elastic electrical connector
that may be adhesively attached to a garment to connect multiple
electrical components.
[0075] FIG. 49 illustrates one example of a sensor (e.g., inertial
measurement unit or IMU) that may be attached to an elastic
connector for a wearable apparatus (garment). In this example, the
IMU is attached by multiple wires (eight attachments, four per
side, are shown).
[0076] FIG. 50 shows an exemplary connection of a PCB (printed
circuit board) and a jack (e.g., female jack connector) to an
elastic connector.
[0077] FIG. 51 illustrates an IMU and jack such as those shown in
FIGS. 49 and 50 connected to an elastic connector as described
herein.
[0078] FIG. 52A shows another example of a haptic actuator attached
to a substrate (e.g., in this example, PCB) that may be integrated
into a garment, as shown in FIG. 52B. In FIG. 52B the haptic
actuator and substrate at attached to a strip of wired fabric, as
described above; this strip, including the sensor (haptic sensor)
may be integrated into the garment as part of the pre-wired strip
of material.
[0079] FIG. 53 is an example of a wiring and sensor
framework/subsystem (spydon subsystem) including multiple elastic
electrical connectors that each contain a plurality of conductive
wires connected or connectable to multiple different electrical
components (e.g., sensors). The subsystem forms a branching
framework of strips that are connected to a controller/processor
(e.g., via an SMS connector) and may be flexibly and readily
integrated into a variety of differently sized and configured
garments. The branches network of connected sensors may be
adhesively and/or otherwise transferred to the fabric to form a
wearable garment.
[0080] FIG. 54A is an exploded view of one example of an electrode
that may be included in any of the apparatuses described herein,
including in any of the strips of material including wiring. This
electrode may be configured, e.g., as an EEG, EOG, etc., electrode.
FIG. 54B shows an assembled view of the embossed electrode without
the cover.
[0081] FIG. 55A is an example of a fabric cover for an electrode
(e.g., an ECG electrode) having a grip pattern. FIG. 55B is another
example of a cover for a longer ECG electrode.
[0082] FIGS. 56A-56C illustrate a method of electrically connecting
an array of electrodes.
[0083] FIG. 57 is an example of a wiring and sensor
framework/subsystem (spydon subsystem) including multiple elastic
electrical connectors that each contain a plurality of conductive
wires connected or connectable to multiple different electrical
components (e.g., sensors). The subsystem forms a branching
framework of strips that are connected to a controller/processor
(e.g., via an SMS connector) and may be flexibly and readily
integrated into a variety of differently sized and configured
garments. The branches network of connected sensors may be
adhesively and/or otherwise transferred to the fabric to form a
wearable garment. In FIG. 57, two vertical (and parallel) strips of
breath sensors are included.
[0084] FIGS. 58A-58I illustrate one method of making a breath
sensor using a silicone conductive cord.
[0085] FIG. 59 is an example of a method of forming another
variation of a breath sensor from a plurality of flat layers.
[0086] FIG. 60A is an example of a temperature sensor that may be
included in any of the garments described herein. FIG. 60B is an
example of the temperature sensor of FIG. 60A integrated into a
garment.
[0087] FIG. 61 is an example of a finished garment including the
sensors described herein.
[0088] FIG. 62A shows one example of a portion of a wiring and
sensor framework for a balaclava garment that may be worn on a
user's head. FIG. 62B is an enlarged view of a portion of the
framework of FIG. 62A, showing the attachment site for the speaker
and the zig-zag pattern of electrical connectors.
[0089] FIGS. 63A-63C illustrate left, front and right side views,
respectively of a balaclava including a plurality of sensors that
may be worn separately or as part of a system of garments including
sensors.
[0090] FIGS. 64A and 64B illustrate front perspective and rear
perspective views, respectively, of a balaclava to be worn on a
subject's head similar to that shown in FIG. 63A-63B.
[0091] FIGS. 65A and 65B show rear and left size views,
respectively, of the balaclava device of FIGS. 63A-64B.
[0092] FIGS. 66A and 66B show right and front views, respectively,
of the balaclava device of FIGS. 63A-65B.
[0093] FIG. 67A shows a schematic of the wiring and sensor
framework similar to that shown in FIG. 62A-62B.
[0094] FIG. 67B illustrates a strip of electrical connector
adhesive that may be used to form the balaclava devices described
herein in which a bundle of insulated wires is sewn (using a sewing
thread, as shown) onto a flexible strip of transparent glue film
support.
[0095] FIG. 68 is a schematic diagram of the components that may be
included in a balaclava device such as the ones shown in FIGS.
63A-67B.
[0096] FIG. 69A illustrates a balaclava configured to acquire and
relay biometric signals from a user that may be used for monitoring
sleep (e.g., sleep staging). The balaclava may be configured to
detect EEG and/or EMG, as illustrated and may include a processor
configured as a classifier to detect awake/nREM sleep/REM sleep,
etc. (alternatively, the processor may be separate from the device
and data transmitted to the remote processor).
[0097] FIG. 69B illustrates a balaclava configured to acquire and
relay biometric signals from a user that may be used for monitoring
mandibular muscle activity supports the diagnosis of bruxism. Thus,
this balaclava is configured to monitor jaw movement (e.g., during
sleep) and/or detect bruxism.
[0098] FIG. 69C illustrates a balaclava configured to acquire and
relay biometric signals from a user that may be used for monitoring
facial/head temperature as well as the bedroom's ambient
temperature, which may be helpful for monitoring sleep.
[0099] FIG. 69D illustrates a balaclava configured to acquire and
relay biometric signals from a user that may be used for monitoring
position and movements of the head (e.g., during sleep). The
separately configurations of FIGS. 69A-69D may be combined in any
combination to provide a head-monitoring device that may be worn,
in particular, during sleep.
DETAILED DESCRIPTION
[0100] In general, descried herein are wearable electronic devices.
Wearable electronics typically include garments that may be worn on
a subject and include one (or more preferable, a plurality) of
sensors that are configured to detect, process and relay biometric
signals for monitoring the user; outputs (haptics, speakers, etc.)
may also be included, and one or more processors may be included as
well. A particular challenge for wearable electronics is sizing.
Because the garments may be used by a variety of different body
types, and because they may be comfortable for use through a
variety of body movements, the garments must be configured to make
robust and reliable contact with the subject's body in a
predictable manner, even while being worn, stretched and otherwise
manipulated by the wearer. In particular, described herein are
methods and apparatuses (including devices, systems, garments,
etc.) that form wearable electronics so that they may be easily
fabricated and may make robust and reliable electrical contact with
sensors on the garment, while positioning the sensors in a
predefined location on the wearer's body.
[0101] For example, described herein are elastic electrical
connector devices for incorporating into a garment to connect
multiple electrical components in the garment, methods of making
these elastic electrical connectors, garments including elastic
electrical connectors and methods of making such garments.
[0102] An elastic electrical connector may be referred to herein as
an elastic strip connector, a fabric strip connector, or the like.
Generally, the elastic electrical connectors described herein may
include a fabric substrate (e.g., cut or formed into an elongate
strip of fabric substrate). This substrate may be elastic (e.g., it
may be made of a stretchable fabric). A plurality of wires may be
attached to one side of the fabric, and the plurality of wires may
be attached in a sinusoidal (e.g., zig-zag) pattern along the
length of the elastic electrical connector. For example, the
elastic electrical connector may include a plurality of wires
extending along a length of the first side of the elongate strip of
fabric substrate in a sinusoidal or zig-zag pattern. The wires may
be attached to the substrate by sewing or stitching. In some
variations, the wires are attached by adhesive (instead of or in
addition to stitching). For example, the plurality of wires may be
attached to the first surface by one or more stitches at the peaks
and troughs of the sinusoidal or zig-zag pattern.
[0103] The garments described herein may be worn by any appropriate
user/subject/patient. As used herein the wearer may be referred to
as a user, patient, or subject, or alternatively, "wearer," and may
include human and non-human (e.g., animal) subjects.
[0104] In general, there may be spacing between the attachment
points at the peak and troughs (e.g., between the stitches) holding
the bundle of wires to the substrate in the sinusoidal or zig-zag
pattern. This spacing may be greater than 1 mm, 2 mm, 3 mm, 4 mm, 5
mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15
mm, 20 mm, etc. (e.g., between about 1 mm and 15 mm); this spacing
may be distance between durable attachment sites (e.g., stitches).
The spacing between attachment points may along the length of the
substrate may vary, or it may be constant. Leaving the bundle of
wires (which may be twisted together) may make the wires easier to
separate out for attachment to an electrical component as will be
described below. Note that even in variations in which the wires
are not referred to herein as attached, the wires of the elastic
electrical connector may be considered as unattached, as the
adhesive may not securely hold the wire(s) to the substrate between
the peaks and troughs. In general, any of the variations described
herein (unless otherwise specified) may include an adhesive on one
or both sides of the elastic electrical connector, including the
side to which the zig-zag/sinusoidal wires (wire bundle) is
attached.
[0105] In some variations the adhesive may hold (or help hold) the
plurality of wires or bundle of wires in the sinusoidal pattern as
described. For example, the plurality of wires may be embedded
within adhesive that holds (or helps hold) the wires in the
sinusoidal (e.g., zig-zag, sawtooth, etc.) oscillating pattern yet
allow individual wires to be removed from the adhesive and the
substrate individually, e.g., by pulling, for cutting and attaching
to an electrical device such as a sensor. In any of the variations
including adhesive, the adhesive may help hold the plurality (e.g.,
bundle) of wires in the oscillating pattern along the substrate
while still permitting individual wires to be removed from the side
(e.g., back) of the substrate for attachment, leaving the other
wires in the oscillating pattern. Thus, the adhesive strength
(e.g., tensile or pull-off adhesive strength) of a wire held to the
substrate (or within the substrate) may be relatively low, allowing
it to be manually removed without damaging the individual wire or
disrupting the oscillatory pattern of the other wires on the
substrate.
[0106] Each of the wires of the elastic electrical connector may be
electrically insulated. In particular, the insulation layer on the
wire may be thermo-removable, so that just heating (e.g., by
soldering, e.g., greater than 200 degrees C., greater than 250
degrees C., greater than 300 degrees C., greater than 350 degrees
C., greater than 400 degrees C., etc.) may remove the insulation
from the wire at the heated portion, leaving the rest of the
wire(s) insulated.
[0107] For example, FIG. 1 illustrates, schematically, one
variation of an elastic electrical connector. In this example, the
elastic electrical connector device includes a strip of elastic
fabric 109, an adhesive 107, and a bundle of wires 102. Any number
of wires (e.g., between 2 and 20, 2 and 19, 2 and 18, 2 and 17, 2
and 16, 2 and 15, 2 and 14, etc.) may be included in the connector
device. In this example, the zig-zag/sinusoidal bundle of wires may
have an amplitude 105 (from trough to peak) of between about 0.5 to
15 mm (or more, e.g., 17, 18, 19, 20, 21, 22, 23, 24, 25, etc.,
mm). The stitch length 103, or distance between trough and peak
along the wire(s) may be between about 1 mm to 15 mm.
[0108] The electrical connectors described herein may allow
deformation (elongation, twisting, curling, etc.) of the electrical
connections. Shortly, this is achieved by embedding a bundle of
electrical wire in a fabric sandwich held together by the
thermo-adhesive. The thickness of the finished spidon may be
important for wearable comfort. For example, the thickness applied
may be between about 0.5 and 2 mm. (typically <2 mm).
[0109] Because of the arrangement of the zig-zag (sigmoidal)
assembly may have material property advantages. For example,
maximum elongation (which is dictated by the mechanical properties
of the chosen substrate fabric) may increase. The geometry of the
ZIG.ZAG pattern is optimized to ensure maximum elongation of the
fabric in the long direction (Zig-zag direction) (i.e., the ZIG-ZAG
is not the weak-link).
[0110] The amplitude and stitch-lengths of the patterns used to
form the elastic electrical connector. For example, the device
(e.g., elastic electrical connector) may be optimized to meet the
above constraint and to support 3000 stress cycles, e.g., having a
guaranteed elongation: of between about 80% to 400. The values for
range of angles between the lines of wire extending between peak
and trough of usually between 30 and 110 degrees.
[0111] The substrate used may be any appropriate substrate. For
example the material used may be, e.g., Lycra, and other synthetic
fibers. For example in some variations the fabric comprises a
mixture of fabrics, such as a mixture of a synthetic (e.g.,
polyester) and another material (e.g. Lycra or elastin), e.g.,
around 25-40% of elastin or Lycra with the remainder being
polyester. The fabric in some ways acts as a limiter, limiting the
maximum stretch of connector to the maximum stretch of the fabric
used, or less.
[0112] As mentioned, any appropriate glue (adhesive) may be applied
to the back of the elastic electrical connector. For example, the
adhesive may be applied to a thickness of between about 20 and 300
microns (e.g., between about 80-100 microns, between about 50-200
microns, between about 100-200 microns, etc.)
[0113] As will be described in more detail below, to connect a wire
to an electrical component, the wire maybe cut and removed from the
bundle at the cut end so that it can be electrically connected. The
wires may be coded (e.g., color/pattern coded), and the proper wire
may be cut (e.g., with a scalpel or scissor) and then when soldered
directly; the application of the solder (heat) may remove e.g., by
evaporation, the insulation. In general, the wires in the bundle
are not fused or enclosed together, but may be secured as a bungle
only at the apexes (peaks and troughs) of the sinusoidal pattern,
e.g., by a stitch. This may allow the wires to be individually
separated and pulled out of the bundle (and out of the stitches
holding the pattern, e.g., by pulling the cut end from the bundle,
allowing them to be easily identified and attached to an electrical
component, such as a sensor or PCB.
[0114] Overall, the strip of fabric forming the device may be cut
into fabric strips of any length and width. E.g., strips may
generally be between 3-4 cm widths (e.g., as thin as possible).
Likewise, the length may be varied. In some examples (e.g., FIG.
2), a roll of elastic electrical connector may be made and cut to
order during fabrication of the garments described herein.
[0115] This elastic electrical connectors may also be referred to
as fabric ribbons or fabric ribbon connectors, and may include the
conductive zig-zag (e.g., sinusoidal) enameled, twisted wires. The
purpose of the elastic electrical connector is to deliver signals
and electricity in every needed part of a garment. There are
numerous advantages to this type of elastic electrical connector:
every single wire/conductor can be easily connected to a sensor, an
electrode or an electronic board without having to strip the wire's
jacket, or remove the fabric protection or others. This is possible
because the strand on enameled, twisted wires (composed from 2 to
up to more than 8 wires) is sewed on the glued side of the ribbon
and can be easily worked on (cut, stripped of protection, welded,
attached, . . . ) before being thermally applied to the garment.
Therefore only a single simple operation is needed in the
production process: removing the cut wire's insulation so that it
can be welded to electrodes, sensors or any electronic or
electrical parts.
[0116] Moreover, this allows us to prepare the "harnesses" with all
the required connections in advance, to test it and to then
`attach` it (the `harness` or SPIDON assembly) to the garment in
one single/efficient/low-cost operation much like is done in the
car manufacturing for the electrical distribution. In contrast to
other devices and methods for connecting electrical components on a
wearable garment, the elastic electrical connectors described
herein are relatively thin (e.g., less than 2 mm, less than 1.9 mm,
less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5
mm, etc.). In contrast, other connectors are too thick which may
prevent the comfort needed in compression or tight clothes. Other
connectors are also described as woven inside the ribbon, thus the
connections can only be done at the beginning or at the end of the
ribbons so many different ribbons are needed. Further, it may be
very difficult and time consuming to cut the ribbon at the desired
dimensions and strip out the wires without damaging them. In some
cases the wires may not have insulation, thus they have to be sewed
separately limiting the ribbon width to the number of wires,
moreover the ribbon risks to generate short-circuit effects when in
contact with sweat or rain.
[0117] The fabrication of the conductive ribbon as described herein
may start with the coupling of a thermo adhesive film with the
fabric: the two coupled materials pass then between two hot metal
rollers that melt the glue onto the fabric side. A fabric reel
normally has a dimension of 140 cm width and a length of about 70
m: after the glue coupling process, the reel can be cut in smaller
reels sized to the desired width (FIG. 1). The ribbon reels come
out with fabric on the external side and glue (protected with
silicone-paper film) on the internal side.
[0118] Using a special custom designed sewing machine, the
conductors strand is sewn over the glue side of the ribbon (FIG. 3)
after the protection film is removed. The sewn ribbon has a
standard length from 5 up to 8 meters depending on the size of the
spool and the capacity of the sewing machine as well as on the
number of wires inside the strand being used. Depending on the
application, the strand can be sewn in the center of the ribbon
(FIG. 4) or on one side (FIG. 5). The center sewing is normally
used for UART BUS distribution where a local uP on board of a PCB
(FIG. 6) or an external connection (FIG. 7) are needed. In FIG. 6,
a separate thread 606 (shown as "center sewing strand" in FIG. 6)
is used to sew the bundle of conductive and insulated wires onto
the strip/ribbon of material. This strand is typically a thread of
material (e.g., non-conductive, non-wire material) that may be
cotton, polymeric (or any blend thereof) and may be stitched over
the zig-zag pattern to secure the tip and bottom (the
peaks/troughs) of the zig-zag pattern to the strip of substrate
material. Stitching with a separate thread of material as shown has
been found to allow the bundle of wires to (collectively or
individually) slide against the strip of fabric which may avoid
puckering or pulling when applied to the stretchable fabric (e.g.,
compression fabric, etc.), allowing more natural movement of the
garment. Thus, the zig-zag pattern shown in FIGS. 6-9 is secured to
the substrate material (strip or ribbon of substrate) using a
separate thread the forms loops anchored through the substrate
fabric strip/ribbon at the peaks and troughs. A continuous thread
may be used to stitch the peaks, troughs or peaks and troughs.
[0119] The side sewing may be used for sensors (FIG. 8, showing a
strain gauge) and electrodes (FIG. 9) connections in the copper
adhesive pads in order to use the free space of the ribbon for
cover and seal the contact area.
[0120] The use of an elastic electrical connector as a garment
electrification method has been tested by an external certified
laboratory with a cycling test bench machine doing a tensile
strength with 20% of elongation to verify the electrical continuity
of the conductors. Note that other (e.g., 30%, 40%, 50%, 60%, 70%,
80%, 90%, 100%, etc.) elongations have been successfully tested
with similar results as well. FIGS. 10A-10C illustrate these
results, which verify that these devices have a surprisingly high
reliability and effectiveness.
[0121] Each single screen test has been applied by thermal transfer
onto a piece of elastic fabric (same fabric material of the ribbon)
with dimensions of 45.times.20 cm. One end of the sample was bound
to the frame of the test device, while the other end was fixed to
the pneumatic piston. The electric wires of the samples, connected
in series each other's, have been connected to the source of direct
current power supply through a current-limiting resistor. Potential
voltage leak at the ends of the wire was monitored by means of a
data logger. The tests have been conducted on three different
screen test samples: one with 4 conductors, one with 6 conductors
and one with 8 conductors.
TABLE-US-00001 TABLE 1 TEST PARAMETERS Distance between jaws 270 mm
Elongation 20% Cycle frequency 1 Hz Number of cycles 3000* Voltage
acquisition frequency 1 Hz *Note: the number of cycles have been
calculated considering one `dressing` and one `undressing` per day,
for a product life duration exceeding 4 years (as a comparison
standard washing cycles are between 40 and 50 times).
[0122] FIGS. 11 and 12 schematically illustrate cross-sections
through six and four strand wire bundles. The wires in this example
are all enameled copper wires that are 0.05 mm/8 strands thickness.
These wires may each be individually color and/or patterned coded,
as indicated by the numeric keys to the right of each figure.
[0123] FIG. 13 illustrates an example of a length of elastic
electrical connector, shown as long, relatively thin (e.g., between
about 2 and 5 cm) and relatively flat (e.g., less than 2 mm). FIG.
14 shows an enlarged view of just the distal end, with the wires
(six are shown) exposed. FIG. 15A is an enlarged view of a portion
of an elastic electrical connector shown connected to a sensor,
specifically a stretch sensor. In practice multiple electrical
components (including sensors, PCBs, microphones, electrodes,
speakers, etc.) may be connected by the elastic electrical
connectors described herein. For example, FIG. 16 illustrates an
elastic electrical connector showing multiple electrical components
electrically connected to the wires of the elastic electrical
connector.
[0124] FIG. 15B illustrates one example of a method of assembling a
strain gauge sensor as described herein, that operates based on
stretch of an elastic impregnated with conductive particles. In
FIG. 15B, the sensor is configured as a breath strain gauge sensor
that is fixed directly to the ribbon band 1509 by two rivets 1511,
1511'.
[0125] In this example, the breath sensor (elastic) is placed,
centered and attached to the middle of a fabric strip 1509 as
shown. The sensor may be attached by keeping the sensor stable,
marking two (or more) holes on the band (e.g., by an awl), punching
through the band to form holes of approximately 2 mm diameter and
fixing the sensor to the strip with two rivets 1511, 1511'. The
rivets may be inserted from the back side of the strip, as shown.
Once attached, the sensor may be covered with another layer, as
shown in FIG. 15C. In this example, a fabric strip 1519 is attached
by applying an adhesive around a perimeter region at one or more
locations 1521 (or completely around the edge). This sensor
configuration may increase the stability of the sensor, allowing it
to work concurrently with the ribbon band forming the sub-assembly
(spidon). The lower and upper strips of fabric (e.g., the lower
strip forming the ribbon band and the covering strip) may form a
pocket in which the elastic sensor may stretch and contract without
interference.
[0126] FIGS. 17A-17F illustrate one method of making a sensor that
may be connected to the elastic electrical connectors described
herein.
[0127] As mentioned above, the connectors described herein may be
part of a system including one or more flexible connectors (which
may be referred to as a "spidon"), that may connect multiple
electrical components, including connecting such components to a
Sensor Management System (SMS), having male and/or female
connectors with their components. The spidon may be configured as a
harness with multiple intelligent strands (e.g., made of twisted
enameled multi (2 to 20, 2 to 18, 2 to 16, 2 to 14, 2 to 12, etc.)
wires sewed against one side of a fabric strip in a sinusoidal
(e.g., zig-zag) pattern, and may include isolating glue. The spidon
may connect and therefore include electrodes, sensors, haptic
actuators, touch-points and ICs such as microcontrollers and IMUs.
A spidon may be designed for garment application where signals
coming from multiple sensors, electrodes, touch points and haptic
actuators placed in different parts of the garment/body have to be
connected to microprocessors placed in different parts of the
garment/body and to (an) external devices such as a Multi Media
Module device (MMM). The SMS connector is part of the Spidon and
may be positioned in the upper center of each shirt, which
corresponds to the center between the wearer's shoulder blades, the
place in the human body less sensitive to weight and to touch.
[0128] The SMS may be placed in each shirt rather than in the MMM.
This solution increases the cost of the system: rather than buying
an MMM with a SMS and use it with many shirts with no SMS, the user
now has to buy a MMM without an SMS and use it with many shirts
each one having an SMS. However this solution allows to increase
the number of sensors, electrodes, touch points and haptic
actuators in the garment without having to increase the size of the
male and female connectors on the MMM. Potential users may not wear
an SMS with more than 36 pins because its size would become too
intrusive and uncomfortable.
[0129] By placing the SMS in the connector glued to the shirt, each
sensor, electrode, touch point or haptic actuator may be directly
connected to the SMS microprocessor through the already mentioned
strands. The SMS microprocessor is then responsible for acquiring
and processing each sensor, electrode, touch point or haptic
actuator data and signals, and for sending those calculations to
the MMM through a digital serial port that requires just two pins
on the SMS connector.
[0130] It should be noted that in case the SMS would have been
placed in the MMM rather than in shirt connector, all the sensors,
electrodes, touch points or haptic actuators would have been
connected to the MMM, thus dramatically increasing the number of
pins on the connector and, as a result, increasing its overall
size. In this case, a high number of sensors, electrodes, touch
points or haptic actuators could be achieved only at the cost of a
bigger connector size. On the contrary, the chosen solution ensures
small connector dimensions and a high number of sensors,
electrodes, touch points or haptic actuators (up to forty-four
connections or more) at the same time.
[0131] In addition to the already described architecture,
additional technology allows the system to increase the number of
sensors, electrodes, touch points or haptic actuators without
increasing the number of strands that need to be embedded into the
garment and connected to the SMS connector. This may be achieved by
using the intelligent dedicated strands that were already mentioned
above. These intelligent strands which connect embed sensors,
electrodes, touch points, haptic actuators and microprocessors that
communicate with the SMS microprocessor in a similar way as the MMM
and SMS are. Each bundle may include multiple strands or wires. For
example, four twisted enameled wires may be used: two wires to
carry signal (e.g., acting as a digital serial communication bus),
and two for the power supply and ground.
[0132] Following a similar principle as the one described for the
SMS, it is possible to consider additional `modules`, each
containing one or more, each additional microcontroller, embedded
into intelligent strands can be then connected to a high number of
different sensors, electrodes, touch points and haptic actuators
placed on the garment. These modules are connected to the SMS by
the strands. The microcontroller, in fact, manages not only sensor
conditioning, but also digital communication.
[0133] In addition to this first advantage, there are two other
important features that should be noted. First, by using this
overall system architecture, the number of wires that go around the
garment is considerably reduced, because the sensors, electrodes,
touch points or haptic actuators are not connected to the SMS but
to the microcontrollers, and also because all the microcontrollers
can share the same digital serial bus for communicating with the
SMS microcontroller. This is possible because each microprocessor
is identified by an address, thus it can be uniquely identified
while communicating with the SMS. The fact that the number of wires
is reduced by this solution, surely improves garment wearability
and comfort for the final users. Wearability and comfort is
important for wearable computers like ours that operate when in
direct contact with a large portion of our skin (entire upper
body/shirts, entire lower body/tights, hands/gloves, feet/socks,
head/balaclava and more) contrary to computers, smart phones that
are used while on desks, in hands or in pockets or intelligent
watches or wrist bands that are worn on our wrists.
[0134] It should be also noted that the number of different
microprocessors that can share the same digital serial bus is
theoretically infinite or very high and limited primarily by the
space on the garment and by the computational power of the SMS
microcontroller that needs to manage all the microcontrollers
placed around the garment (including the interrogation frequency,
bandwidth, etc.).
[0135] Lastly, the combination of microcontrollers, sensors,
electrodes, touch points or haptic actuators connected to it,
allows to create a sort of "smart sensorized node" that can be
managed independently from the SMS and can help to distribute the
data processing and to relieve the SMS microcontroller processing
load.
[0136] Referring to FIG. 21, the connector body (a1) is made off
polycarbonate plastic material with an overall thickness of 2 mm in
order to guarantee shock protection. At the base there is a flat
flange (a2) which allows a good stability on the soft plastic layer
support (b1) which is hot-melted to the garment fabric (b2). One
additional purpose of this flange is to fix the connector to the
first plastic layer through an additional layer (b3) which is
hot-melted to the flange in order to `sandwich` the connector to
further stabilize it. The final assembling is shown in FIG. 22.
[0137] In FIG. 23, the SMS connector has four magnets (a3) placed
at the four corners cylindrical seat (a4) that allows to lock
easily and to stabilize the external device to be connected. This
connector has a 68 IP grade to be completely waterproof to endure
regular washing (it is an `intelligent` garment thus needs to be
regularly cleaned after use), thus the magnets are positioned at
the back side of the surface in order to avoid possible oxidation
and rust deposit.
[0138] In FIG. 24, despite the matching position between the
external device and the SMS connector is constrained, on both sides
right and left, is present a semi-cylindrical slot (a5), designed
to avoid unwanted reversed connections.
[0139] The connector may also be made waterproof, e.g., or at least
water/moisture resistant, as shown in FIG. 25. The female contacts
receptacle has been designed to avoid any water access to the inner
parts. After the female contacts (a6) insertion in the
corresponding pinhole, the back side of the connector is filled
with epoxy resin (b4) in order to seal completely any
interstice.
[0140] One basic pins configuration is shown in FIG. 24 with 12
poles, but it could also be configured with 16, 20, 24 and 28 poles
as shown in the variations of FIG. 26 (showing, 20, 24 and 28,
respectively).
[0141] FIG. 27 illustrates the electrical connections between the
SMS (Sensor Manager System) connector and the external Multimedia
Module device (MMM) are through female contacts (a6) and pogo pins
(b5) that thanks to the internal spring ensure stable and reliable
electrical contacts even under extreme shocks and vibrations.
[0142] FIGS. 28-31 illustrate an SMS. The SMS shell shown contains
a printed circuit board assembly (PCBA) (FIG. 28), directly
soldered to the female contacts and acting as a central unit able
to acquire and process data and signals from sensors, electrodes,
touch points or haptic actuators embedded into the garment and
transmit them to the MMM.
[0143] The SMS main component is a microcontroller. As already
mentioned, the main purpose of this microcontroller is to manage
the acquisition of data and signals coming from sensors (e.g. ECG
electrodes, EMGs, string gauges, skin conductance, IMUs, etc.),
electrodes, touch points or haptic actuators. The same component is
also involved into a first phase of data processing (e.g. digital
filters) and into the communication of these calculations to the
Multimedia Module through a serial digital line.
[0144] In one example, shown in FIG. 29, twelve pins (female
contacts) ensure the electrical connection. These pins are used for
having the digital communication, the power supply coming from the
Multimedia Module battery (regulated +3.3V and protected VBAT) and
other hardware features (e.g. sensing of the connection between
Multimedia Module and SMS). In FIG. 30A, the SMS PCBA solder layer
has been designed to allow several connections to various types of
sensors, electrodes, touch points or haptic actuators distributed
throughout the garments to cover the body specific parts (arms,
hands, legs, feet, shoulders, head, thorax, back, abdomen, etc.)
through a special harness made with elastic ribbon to which is
sewed a strand of 2 to 12 (or more) enameled conductors/wires. The
strand (bundle of wires) is sewn at the peak and trough of the
zig-zag pattern, with each side in this example measuring from a
minimum of 2 mm to a maximum of 4 cm and with angles between
1.degree. and 179.degree. in order to allow the ribbon to stretch
from 10% to 500% of its length. The ribbon band is made with the
same fabric utilized to make the part of the garment (sleeve,
shoulder, etc.) where it is applied. Since stretchable fabrics
stretch in various directions (from 1 to 6 or more) the ribbon is
applied following the exact stretching direction of the part where
it is applied. This process ensures that the ribbon has the same
elongation and the same return as the fabric where it is applied to
improve functionality (conductivity and data collection) and
comfort in wearing the garment. It also improves the looks of the
garment (seamless stretching and return of the garment when body is
in motion). The elastic ribbon is glued to the stretchable fabric
through an adhesive film especially formulated for fabric
applications, this adhesive is on the same wiring layer and it is
used for hot fixing to the garment's elastic tissue in order to
block and keep the zig-zag strand shape after hot application. The
zig-zag shape has been optimized to assure the wires elongation
during donning and usage avoiding the mechanical stress of the
copper conductive material.
[0145] FIG. 30 B is another example of an SMS housing that may be
used to secure a controller (SMS controller) that is configured to
allow it to securely housing the controller and allow it to
interface with a plurality of inputs, e.g., from flexible ribbon
connectors, without pulling the wires out of the controller. In
FIG. 30B, the SMS connector housing (shell 3009) allows the SMS
circuitry (controller, not visible in FIG. 30B) to rest snugly
within the housing so that a seal may be provided over the
connectors between the wires 3907 and the circuitry. In FIG. 30B,
the cover is not shown over the SMS housing; before the back cover
is attached, the SMS may be coated with a region of epoxy resin. A
sealant 3005 such as a ring of Down Corning silicone may be placed
all around the wires strands collected in the center of the PCB.
This silicone 3005 crown may allow the wires exit gently from the
SMS connector shell, retained in position, and may also provide
some degree of water resistance to the connections.
[0146] In any of the connectors described herein in which the
insulated wires are sewn onto the substrate, a separate thread
material (e.g., cotton, polyester, blend, etc.) may be used to sew
the bundle of wires against the substrate (fabric) at the
appropriate regions. A single loop of thread, or multiple loops of
thread may be used to hold the wires in place. The thread may pass
around the bundle of wires one or more times, and through the
substrate one or more times. The stitches securing the wires to the
substrate may be separated by a spacing distance (e.g., see FIG. 1,
element 103).
[0147] The wired elastic ribbons connect different sensors types
as: IMUs, EMGs, electrodes, touch points, ink sensors by conductive
washers connections (e.g., FIG. 31), haptic actuators, PCBA (FIG.
10) and any kind of electrical connections.
[0148] In case of PCBA incorporation, this must be previously
covered by epoxy resin to prevent any water, sweat or any kind of
liquid penetration inside the electronic circuit. The coverage has
a smooth and rounded shape in order to have a good touch feeling
and an attractive appearance from the external side of the
garment.
[0149] The conductive washers may be used for connect the copper
wire, soldered on it, to the ink sensors and are made by
silver-chloride thin steel film in order to have a strong bending
resistance and good protection against rust and oxidation,
maintaining optimal conductivity values. The coupling between the
washer and the ink surface is made thanks a special conductive
adhesive named z-axis (manufactured by 3M) that allows transmission
of electrical signals between the two different material
surfaces.
[0150] With this system, it is possible have also input/output
electrical connections, like connectors or external modules in
every parts of the garments thanks to the "splitter PCB" (SPP) that
allows the connection of the thin enameled conductor to standard
harnesses. As per the PCBA, the SPP must be protected by epoxy
resin coverage after cabling. FIG. 32 illustrates a connector
electrically connected to a pair of electrodes.
[0151] All the wired ribbons terminations are soldered to the SMS
PCBA pads on the Solder layer and, after test, are incorporated by
epoxy resin inside the SMS connector shell (FIG. 33) in order to
completely prevent water penetration. A Spidon subsystem (e.g.,
FIG. 34, FIG. 35) may then be ready to be coupled with the garment.
First of all the SMS connector may be inserted through a slot
present on the high back side of the shirt and mechanical fixed to
the garment as described above (e.g., FIG. 21), then following the
draw projected by a laser projector, the various wired strips may
be positioned to the right place of the internal garment surface
and using a hydraulic press for thermo printing, fixed to the
tissue.
[0152] FIG. 35B illustrates another example of a subsystem
including a plurality of elastic electrical connectors that each
include a plurality of wires arranged and attached as described
herein (e.g., including a plurality of wires extending along a
length of a first side of an elongate strip of fabric substrate in
a sinusoidal or zig-zag pattern, wherein each of the wires is
electrically insulated, and wherein the plurality of wires are
attached to the first surface by a stitch at a peak and a trough of
the sinusoidal or zig-zag pattern). In this example the subsystem
includes seven branches (strips) that all connect at one end (a
proximal end) to an SMS controller 3505 (held in an SMS housing).
Each branch may include one or more sensors 3517 and/or IMUs 3515
(which may, e.g., process data from the one or more sensors and
prepare it for transmission to and by the SMU 3505). The strips
forming the subsystem may then be attached or otherwise integrated
into a garment (sewn, glued, embedded, layered, attached, etc.),
such as a shirt, e.g., a t-shirt having long or short sleeves,
including but not limited to compression garments. In FIG. 35B, the
subsystem includes connectors for a left 3507 touch sensor, a right
touch sensor 3507', a left arm 3509, a right arm 3509', a left back
3511, a right back 3511' and a center back region 3513. The
different connectors may have different lengths and may connect to
different components, as illustrated.
[0153] Other examples of SMS and SMS connectors are shown in FIGS.
36-39.
[0154] FIGS. 40A-40C illustrate other examples of flexible
connectors having a wires attached in a sinusoidal or zig-zag
pattern. In these example, one or a bundle of fibers is attached
(including sewn into the fabric, rather than using an additional
thread to sew the wires onto the substrate as described above in
FIGS. 1-39). Thus, these embodiments may not have all of the
advantages, including ease of removing and connecting a wire, as
described above.
[0155] In some variations it may be useful to use conductive
threads or other high-conductivity connectors, such as those shown
in FIG. 40A-40C. In this example, the conductive thread is stitched
onto the garment in a wavy (e.g., zig-zag, sigmoidal, etc.) pattern
that allows some stretching in the net direction of the stitching.
As described above, respiration (sensors) traces may be formed of
stretchable conductive ink patterns to take advantage of the change
in conductivity with the change in resistivity with stretching of
the conductive ink pattern. In this example, the sewn pattern of
threads includes an approximately 35-40 degree zig-zag pattern
allowed the stitch to elongate slightly with the fabric. In some
example, the conductive thread is a metallic conductive thread. The
angle formed at each turning point (in the wavy pattern) and the
width of the pattern may depend upon the textile used. In general,
the higher the stretchability of the textile, the smaller the
angle. The number of threads may vary; in general, any number of
threads may be used depending, for example, on the number of
sensors and their pins that need to be connected. The threads are
typically sewn directly on the garment. The electrical insulation
of the thread may be obtained by an external coating on the thread
(e.g. silicone, polyester, cotton, etc.) and/or by a layer of
insulating adhesive, as described above. The thread connectors may
also be used as part of a transfer as described above. For example,
a conductive thread may be sewn on a band made on the same fabric
of the garment and then transferred by a thermal process to the
garment, e.g., using a layer of adhesive.
[0156] One or more conductive threads may be applied directly to a
fabric (such as a compression garment) or to a transfer (e.g.,
patch of fabric or other material that is then attached to the
garment). Conductive threads may be insulated (e.g., enameled)
before being sewn. In some variations the conductive thread may be
grouped prior to sewing onto a fabric or other substrate. For
example, a plurality (e.g., 2, 3, 4, 5, etc.) of threads may be
insulated and wound together, then stitched into a substrate, such
as the compression fabric. For example, in one variation, an
apparatus includes a garment having an IMU and two EMGs with inputs
fed into circuitry (e.g., microchip) on the apparatus, including on
a sensor module/manager. The components may be operated on the same
electronic `line`, where the line is a a plurality of electricall
conductive threads that are combined together for stitching through
the substrate. In one example, two microchips can be operated by
the same `line` made of 4 wires, where each wire is electrically
isolated from each other. In stitching a material, the stitch may
be formed of two sets of wires; one on top of the substrate and one
beneath the substrate, as is understood from mechanical sewing
devices; in some variations a stitch formed of conductive thread
may include an upper conductive thread (or group of conductive
threads) and a lower conductive thread (or group of conductive
threads), where the upper conductive thread(s) is primarily on the
upper surface and the lower conductive thread(s) are primarily on
the lower surface (but one or either may pass through the substrate
to engage with the other).
[0157] For example, a conductive thread may include a very fine
(e.g., 0.7 millimeters gauge/thickness) `wire` made of 4 twisted
and enameled (thus electrically isolated from each other) wires
covered with a binding solution (that is silicon or water based) or
protected by a jacket, having a total diameter of about 0.9
millimeters. A conductive wire may be sewn in a wavy (e.g.,
zig-zag) pattern, such as a pattern having 45 to 90 degrees angles
between the legs of the zig-zag, directly on a fabric or substrate.
In some example, the pattern is formed on a substrate of material
(e.g., fabric) and attached to the garment. For example, the
substrate may be a 1 cm to 3 cm self-adhesive strip of fabric.
[0158] FIGS. 41-48 illustrate the connection and formation of one
type of sensor to an elastic electrical connector as described
above. In this example, a stretch sensor may be formed by
impregnating an elastic material with conductive particles,
allowing it to dry and then coupling contacts at the ends, to form
terminals. Once the terminals are attached, the elastic material
may be coupled to a wire connector, such as the pre-prepared wire
ribbon material shown in FIG. 41. In FIG. 41, a wire ribbon
material is sewn into a strip of fabric with a pair of twisted
wires 1010 (though more than two wires may be used), shown as
twisted, enameled (insulated) wires. The wires are sewn into the
strip of fabric (e.g., compression fabric) in a zig-zag pattern and
the fabric strip may include a fabric adhesive or may be configured
for thermally applying to another fabric (e.g., garment), so that
the conductive connectors can be applied directly to the fabric
without having to sew directly onto the fabric, and providing a
covering for the wires. The fabric onto which the wires are sewn is
typically the same material to which they are to be applied (e.g.,
a compression garment fabric). In some variations one side of the
fabric onto which the zig-zag pattern of insulated wires is sewn,
which may be referred to as an applicator fabric, include or is
treated for use with a fabric adhesive (including thermally active
adhesive). In practice, long lengths of wire may be prepared ahead
of time and cut to need for application to a garment. Note that in
general, a wire ribbon material may be used as an electrical
connector connecting one or more sensors to other portions of the
garments described herein, including a data module, and/or an SMS
component. This wire ribbon material may be referred to herein as a
wire ribbon material or as a stitched zig-zag connector. This
material may be advantageously prepared in long lengths and cut to
the desired length for securing (e.g., adhesively securing) the
garment and/or sensor.
[0159] For example, in FIG. 42, the conductive elastic ribbon is
place on a thermo adhesive glued surface of the wired ribbon in a
region that does not include wire, and connected to the conductive
wire ends. For example, as shown in FIG. 43, the conductors (wires)
are soldered to the copper terminals.
[0160] Once applied to the conductive wires, the elastic ribbon may
be enclosed within a fabric (e.g., an insulating fabric, which may
be the same as the fabric to which it's being applied). In some
variations the elastic ribbon may be enclosed in an insulator
material and/or coated with an insulator. In FIGS. 44 and 45 the
external side of the conductive elastic ribbon (including the
contacts) is sealed with an adhesive tissue ribbon to a width of
approximately 33 mm). The tissue (covering) ribbon may be fixed
over the elastic ribbon by, e.g., thermo press (when using a
thermally activated adhesive) as shown in FIG. 45.
[0161] Thereafter, the resulting ribbon including the conductive
elastic material and zig-zag wires may be attached to a garment,
such as a compression garment.
[0162] FIG. 49 is an example of a sensor that may be integrated
into an elastic connector as described herein. In this example, the
sensor is an IMU, although any sensor may be used. Multiple IMUs
may be attached to the subsystem (as shown in FIGS. 35A and 35B),
which may provide body movement and/or positional information when
the garment is worn. For example a sensor may be on or part of a
printed circuitry board such as the IMU shown in FIG. 49 (or an EMG
sensor or conditioning circuitry). Attachment between a flexible,
stretchable fabric and a somewhat more rigid PCB may typically
result in a poor connection which may vary in resistance as the
wire(s) is/are bent during normal movement/wear of the garment. In
FIG. 49, the PADs 4901 onto which the insulated wires of the
connector are attached are arranged in a fanned, semi-circular
arrangement, so that the wires may remain bundled 4911 until they
reach the center of the semi-round seating region (e.g., remain
gathered together), as shown, then individual wires spread out and
are attached to the contacts (PADS 4911). Similar connections may
be made on both ends of the circuitry. In some variations wires
that are not connected to the circuit (e.g., sensor) may be
separated before reaching the fan-out region at the vertex 4915 of
the semi-circular PAD arrangement, and may pass on the strip,
around the sensor/circuitry (not shown).
[0163] FIG. 50 is another example of a circuitry (PCB) that may be
connected in a similar fashion to the flexible/stretchable fabric
connector strip. In FIG. 50, a female plug 5019 may be connected to
the strip. The female jack connector in this example includes two
added wings that may improve the Jack connector stability and the
fixing to the ribbon. In this example, the insulated wires from the
connector strip remain bundled 5011 until they reach a central
vertex region 5015, where they then fan out to contact the PAD
contacts arranged in a semi-circle that fans out around a common
vertex 5015. By connecting the wires of the flexible fabric strip
to the more rigid substrate and contacts of a sensor or other PCB
(e.g., the connector 5019 shown in FIG. 50) in this manner, stress
may be distributed in a way that prevents resistance changes and
disconnection of the wires.
[0164] It may also be beneficial to coat the contact region
(including the vertex 4915, 5015 and PAD contacts 4909, 5009) with
a polymer, such as a silicone. For example, in both FIGS. 49 and
50, a Dow Corning silicone has been placed in the circular seat
wire connector regions, keeping the wires in suspension so that
they may exit gently from the PCB as a cable boot. The silicone may
be accurately and easily applied because of the semi-circular
arrangement, and may help insulate and protect from water as
well.
[0165] In FIG. 51, the sensor (e.g., IMU 5103) and circuitry
(processor 5105 with connector 5107) such as those shown in FIGS.
49 and 50 are shown connected to a flexible fabric connector, as
illustrated above. In this example, the fabric (e.g., compression
or stretchable fabric) 5101 is formed as a strip and has an
adhesive on one or both sides (e.g., on the visible side shown in
FIG. 51). As just described, both the sensor and the connector, via
the circuitry 5105, are attached to some of the wires coupled to
the fabric in a zig-zag pattern, as shown.
[0166] Any of the methods (including user interfaces) described
herein may be implemented as software, hardware or firmware, and
may be described as a non-transitory computer-readable storage
medium storing a set of instructions capable of being executed by a
processor (e.g., computer, tablet, smartphone, etc.), that when
executed by the processor causes the processor to control perform
any of the steps, including but not limited to: displaying,
communicating with the user, analyzing, modifying parameters
(including timing, frequency, intensity, etc.), determining,
alerting, or the like.
Additional Examples
[0167] The methods and apparatuses described herein may be
configured for use with or as part of a wearable electronics
garment that includes a plurality of sensors. One improvement
described herein is the use of a strip of fabric, configured as a
framework that includes wiring and sensors preformed and connected
thereon. The framework may be made attached into a garment, and
allows flexibility in construction, testing and finishing. As
described above, the framework includes strips or ribbons of
substrate, which may be the same or a different material from the
rest of the garment to which it is attached. These ribbons may
include wire bundles that are then connected to the sensors and/or
outputs on the strips and attached to the garment. Rolls of the
wired ribbon (with flexibly and slideably attached zig-zag wire
bundles) may be formed and variable lengths later cut and used to
form a variety of garments having different shapes and sizes.
[0168] In addition, the ribbons including the flexible and
slideable bundles of insulated wires may also have one or more
sensors and/or outputs (e.g., electrodes, haptics, accelerometers,
temperature sensors, speakers, capacitive touch sensors, etc.)
formed on the strip of material or attached to an adjacent strip of
material. For was illustrated above in FIGS. 6-9, 16 and 31-32,
35A-35B, 42-45 and 51. FIGS. 52A-52B illustrate another example,
showing a haptic actuator that may be included. In FIG. 52A, the
haptic actuator 5203 is shown on a substrate (e.g., PCB, which may
include a protective coating such as a transparent resin coating)
5201, and is assembled on the substrate with component circuitry,
such as a filter diode 5205 and control circuitry. As show in FIG.
52B, the haptic actuator assembly on the substrate 5200 may be
connected to the ribbon or strip including the electrical
connectors arranged in a zig-zag pattern 5208 as previously
described. Thus any of the ribbons described herein may be formed
with one or more sensors and/or outputs connected to the conductive
wires arranged on the ribbon. These may then be joined into the
framework when assembling the device, such, for example, the
framework ("spidon") shown in FIG. 53.
[0169] FIG. 53 shows an example similar to that shown and described
in FIGS. 35A-356B, discussed above. In FIG. 53, the framework is
formed by cutting strips of connector ribbon to which one or more
sensors have been coupled to a desired length and arranging them in
the framework to be attached to the garment. In this example, the
framework includes lengths of ribbon to which bundles of insulated
wire are attached as discussed above, and conned to t electrodes or
other sensors. For example, left 5301 and right 5303 arm strips of
ribbon each have an electrode 5305, 5305' on either end. Each strip
may ultimately electrically connect to an SMS unit 5309 for
processing/storage/transmission of data from the sensors and/or
outputs. Other branches of the framework formed by the connected
ribbons include right 5311 and left 5313 leg electrodes as well as
left 5315 and right 5317 thorax breath sensors that are configured
to be attached across the front of the garment. An abdominal breath
sensor 5319 as well as left 5321 and right 5323 abdominal breath
sensors may also be included to detect respiration. In FIG. 53 the
chest strips also include a plurality of ECG electrodes (V1-V6)
arranged to detect ECG at or near standard ECG electrode placement
positions.
[0170] Any of the electrodes for contacting the wearer's body
described herein may be configured as an assembly of electrodes.
For example, FIG. 54A-54B illustrate an embossed electrode
configured for EEG, EOG, EMG and/or ECG. In FIG. 54A the electrode
assembly is shown in an exploded view including an electrode cover
5401, a conductive ink 5403, an electrode support 5405, a
compressible contact support 5407 (shown here as a sponge foam for
increased contact to skin and therefore conductance). And an
electrical limiter (e.g., insulator) 5409. FIG. 54B shows an
example of a partially assembled electrode 5411, without a
cover.
[0171] Any appropriate covers may be used. The electrode cover may
be particularly helpful to keep the electrode in contact with the
wearer's skin. For example, FIGS. 55A and 55B illustrate electrode
covers that are configured to include a grip pattern on the
surface. In this example, the electrode covers are formed of a
fabric material onto which a pattern of micro protrusions (e.g.,
balls, spheres, etc.) of a high-grip material such as silicone or
polyurethane material has been applied by an extrusion or print
process. These micro balls may help assure a good adhesion of the
electrode to the skin in order to have a stable biometric signal.
This pattern may also allow the sweat to drain from the skin
surface (e.g., a pattern having gaps, rows, columns, etc.) as
shown. The gaps may be spaced to be >0.1 mm (e.g., 0.1 mm or
more, 0.2 mm or more, 0.3 mm or more, 0.5 mm or more 1 mm or more,
etc.) apart. In FIG. 55A, the fabric support 5501 is a soft fabric
support with an adhesive on (or may be applied onto) one side. The
cover includes a window 5503. As mentioned, the plurality of grip
protrusions 5505 may be attached or formed onto the skin-facing
surface. FIG. 55B shows a similar variation with a larger window or
opening for the electrode.
[0172] As mentioned, sensors, such as electrodes, may be attached
to the electrical connectors on the strips/ribbons of material and
used to form the framework for attaching to the garment. FIGS.
56A-56C illustrate one method of attaching a set of electrodes,
similar to that shown in FIGS. 17A-20, above. In FIG. 56A, the
conductive metal pads 5601 may be stuck onto the ink aps of the
electrodes, as shown. These conductive metal pads may then be
tinned 5603 (as shown in FIG. 56B) and a de-insulated end of the
wires may be soldered 5605 to the conductive metal pads, as shown
in FIG. 56C.
[0173] FIG. 57 is another, somewhat alternative, versions of the
framework for forming a garment having a plurality of sensors
similar to what is shown in FIG. 53. In FIG. 57, an alternative
respiratory sensor is used, formed of a conductive cord, as will be
described in greater detail below in reference to FIGS. 58A-58I. In
this example, the apparatus includes the right 5701 and left 5703
arm electrodes and SMS 5709, as well as the right 5707 and left
5711 leg electrode (which may connect the lower back or upper
buttock region when worn in the garment). Similar ECG electrodes
(V1-V6) are shown. A plug 5721 (e.g., 5 pole female plug) may also
be included. The respiratory sensors in this example, include ends
that are connected by two parallel strips 5725, 5725' with ends at
the level of the thorax, xiphoid, abdominal upper region, and
abdominal lower region. The conductive cord, which is an elastic
conductive cord, may be attached at either ends (e.g., between
these parallel vertical strips 5725, 5725'). For example, the
signal ends of the thorax 5731, xiphoid 5733, upper abdominal
region 5735 and lower abdominal region 5737 are on the right side
5725' strip, while the ground end terminals of the thorax 5741,
xiphoid 5743, upper abdominal region 5745 and lower abdominal
region 5747 are on the left side strip 5725. As shown in FIG.
58A-58I the conductive cord may be connected between the signal and
ground ends.
[0174] In FIG. 58A, a length of electrically conductive cord 5801
(e.g., a cord or tube formed of a conductive silicone rubber that
includes an outer insulator) is shown. A connector (e.g., ring
terminal) may be placed on either rend of the length. The length x
may be cut to a predetermined length based on the size of the
garment, and the terminals 5803 attached to either end (e.g., by
crimping, etc.). The conductive cord may then be coupled to a
support 5809 (with or without a rigid or semi-rigid substrate 5811,
as shown in FIGS. 58C (and side view 58D) and 58E (and side view
58F). A connector 5813 (e.g. rivet) may be used to connect the
conductive cord ends to the limiter support (substrate 5809). The
other end may be pulled through a channel (e.g., a fabric channel
that is attached or to be attached to the garment. The attachment
end may then be coupled to the framework (e.g., FIG. 57) and an
electrical contact made through the connector. See, FIG. 58G. The
opposite end may then be connected to a support substrate and
connector, as shown in FIG. 58H, and attached to the opposite strip
(e.g., 5725' in FIG. 57), as shown in FIG. 58I. The connections may
be sealed (and insulated). A fabric cover (sensor cover) may also
be applied over the ends.
[0175] In operation, the electrically conductive cord may provide a
stretch sensor that changes an electrical property (e.g.,
resistance) with stretch within a relatively linear range that
provides a sufficient measure of respiration based on the
stretching and relaxation of the cord during breathing while
wearing the garment. The electrically conductive cord may include
conductive carbon fibers.
[0176] FIGS. 60A-60B illustrate another example of a type of
sensor, shown as a temperature sensor, that may be used. In this
example, the temperature sensor is assembled on a rigid or
semi-rigid support 6001 (e.g., PCB) and includes a temperature
sensor 6003 (e.g., PCBA) and a transparent sealing cover 6005. In
FIG. 6B the sensor is show integrated into a garment. For example,
the sensor may be attached directly to the garment or to the
strip/ribbon with the electrical connectors, as described above. In
FIG. 60B, the sensor 6003 is connected to a transparent glue film
support 6009 to which ultralight zig-zag bands of connectors 6013
have been attached as well, and a fabric ring protector cover 6011
is attached over the sensor.
[0177] FIG. 61 shows an example of a finished garment 6101 that
includes a framework of ribbons with conductive wires attached in a
zig-zag pattern and sensors has been applied to a base fabric 6103
that is a compression material. The final garment also includes
calibrated sets of straps 6103, 6105 for tightening halter-like
framework to the patient's body, allowing snug contact with the
skin, as well as a belt 6109. A side zipper 6115 may be used to put
the garment on/off. The armpit regions are shown without fabric
(opening 6117), to avoid getting perspiration on the garment,
reducing the need to wash it, although it generally is
washable.
Balaclava
[0178] FIGS. 62A-69D illustrate one example of a garment with a
plurality of sensors that may be worn by a patient. This garment is
configured as a balaclava to be worn on the patient's head, and may
include a variety of different sensor and/or outputs, including a
speaker over or near the user's ear(s). The same principles
described above, including the ribbons formed with bundles of
insulated electrically conductive wires arranged in a zig-zag
pattern may be used, and the ribbon may have a smaller width. FIGS.
62A and 62B illustrate an example of a framework ("spidon") for a
balaclava garment. In this example, to increase the wearing comfort
of the Balaclava harness/framework, a conductor distribution system
including the zig-zag wire bundles is used; however these wires may
be sewn directly on the fabric band. For example, the wires 6205
may individually or as a bundle be sewn first on a thin glue
transparent ribbon and then applied to the fabric band on the glue
side. The fabric band shown 6203 has been cut with a custom shape,
both for left and right side, in order to avoid sharp bends. A
speaker 6209, 6211 may be attached (in FIG. 62B, both the front
6211 and back 6209 views of a speaker to be attached to the
electrical connections 6207 are shown).
[0179] In general, the balaclava apparatus may be part of a garment
adapted for use when sleeping. Sleep has a critic impact on human
health. Getting a good night's sleep is essential to feeling
vigorous the following day. The challenge is to define what a
"good" sleep is. Biometric signals can be exploited to infer
indices of clinical relevance which describe the structure of the
sleep, highlighting different phases, patterns, transient events
and possible pathological conditions.
[0180] The balaclava apparatus shown in FIGS. 63A-63C is a wearable
device able that acquires biometric signals from the user's head,
as well as ambient parameters, through a set of embedded dry
electrodes and sensors. The acquired signals may include: EEG(2):
two frontal channels, Fp1-M1 and Fp2-M1; EOG(2): left eye and right
eye; EMG(3): chin, left masseter and right masseter; Head's
position/motion; Frontal temperature; and ambient temperature.
[0181] The apparatus may be connected to additional garments
measuring other body parameters, and may be a complementary tool
for polysomnographic monitoring and sleep studies: the acquired
signals are useful to implement a sleep report and to infer
nocturnal unconscious behaviors. An additional feature of the
apparatus is the possibility of providing relaxing, acoustic
stimuli to the user or to stream music as a sleep aid, by
exploiting a pair of embedded earbuds.
[0182] Target users may be subjects with either diagnosed or
suspected sleep disorders, subjects who need a sleep aid or
subjects who want to "quantify themselves" even in complete,
unconscious conditions. FIGS. 64A-64B show front and rear
perspective views of the apparatus worn on a user. The garment is
configured as a fitting cap which completely covers the user's head
except for eyes, nose, mouth and the back of the head. The cap has
an opening on the nape with an adjustable fastening mechanism. This
element allows for easy wear ability: the user wears the Balaclava
by inserting their face into the large opening on the back, then
gently fits the fabric over the face and head, finally fastening
the mechanism on the nape according to his particular neck
size.
[0183] As shown in FIG. 65A, the fastened garment may include an
opening at the crown of the head for users with long hair. Openings
over the ears (shown in FIG. 65B) may be used for the positioning
of the mastoid electrodes just behind the ears, in the correct
mastoid area. Moreover, ear cuts may be configured so that the
embedded earbuds lean over the ears comfortably. In the examples
shown in FIGS. 64A-66B, an elastic band runs over the face outline,
hidden in a thermal welded fabric channel. Adjustable mechanisms
allow for the user to tighten the elastic band to improve the
adherence of the electrodes to the skin. A thermal welded fabric my
contour the face opening to improve skin comfort, as shown in FIG.
66B.
[0184] On the top of the garment, a light-plastic case may be
attached to the fabric with a thermal, welded patch. The case may
hold electronics board and it has inlets for the passage of the
cables.
[0185] A breathable fabric insert, present on both the sides,
improves the user's comfort to allow skin transpiration. The
garment may be available in different sizes and it is completely
washable, even with the embedded electronics.
[0186] FIG. 67A illustrates one possible layout of a balaclava
apparatus, including various sensors/electrodes (labeled by color,
red, gold, blue, green) that may be used. In FIG. 67B, an example
of a ribbon connector including a zig-zag pattern of insulated
wires that are stitched into the transparent glue film support are
shown. In this example, the ribbon is a narrow support band
(approximately 15 mm instead of 30 mm shown in examples above), and
it includes only a glue film instead of glue and fabric. This
configuration is simple to bend horizontally for angled paths
needed.
[0187] In general, the balaclava apparatus may include a set of dry
electrodes and sensors for the acquisition of biometric signals,
electronics for sensors management, a pair of earbuds and
anti-shock circuitry to manage sound experience, a 5-poles jacketed
cable to connect the device to L.I.F.E. CTS-Med: biometric data
streaming, and a 4-poles jacketed cable to connect the device to
Grivola: audio streaming. FIG. 68 illustrates one example of a
qualitative schema involving the hardware components. In this
example, the PSoC5 (Cypress) is a microcontroller which manages
sensors sampling and data transfer to Master device (Grivola). The
ADS1298 (Texas Instruments) is an analog-front-end for the
digitalization of the analog signals from electrodes. MPU9250 (TDK)
is an IMU. The LMT70 forehead (Texas Instruments) is a sensor for
user's forehead temperature monitoring. The LMT70 ambient (Texas
Instruments) is a sensor for ambient temperature monitoring. The
Speaker SX, speaker DX are earbuds. The electronic board may be
held into a soft-plastic case on the top of the garment. Cables
from the "Ultra light Zig-Zag Band" (e.g., FIGS. 62A-62B and 67B),
which wire the electrodes, may be soldered on board pads as well as
both the 4-poles and the 5-poles jacketed cables; Potting cover is
spread on the board in order to provide mechanical protection and
waterproof properties. Firmware may be used to implement sensors
sampling and data transfer to the Master device (Grivola) on
data-request messages. In some variations a smartphone App
(applications software) may provide a user interface for the
management of polysomnographic monitoring and audio streaming. A
web App may include a set of algorithms for off-line signal
processing which yields polysomnographic indices.
[0188] The user's experience may involve a multiparametric
monitoring during sleep, followed by an off-line analysis of the
acquired signals which produces a sleep report. The device may, for
example, be part of an asset (do you mean `a set`) which implements
a complete polysomnography. In some variations, the user wears both
a monitoring garment (such as those shown and described above,
including the shirts e.g., FIG. 61), and the Balaclava. They plug
the Balaclava connectors to CTS_Med and to the Grivola. Then they
go to bed and start a polysomnography recording through the proper
App in their smartphone. They are allowed to select one or more of
the following functions: (1) Sleep staging (using a configuration
as shown in FIG. 69A, e.g., relying on the acquired biometric
signals, a sleep staging report is performed. Signal parameters
drive a classification into "awake", "nREM sleep" and "REM sleep"
classes); Bruxism detection (using a configuration as shown in FIG.
69B, e.g., seamless monitoring of mandibular muscle activity
supports the diagnosis of bruxism); (3) temperature monitoring;
and/or (4) head position monitoring. The user's frontal temperature
as well as the bedroom's ambient temperature are both monitored in
order to study the temperature trends, patterns and correlations
during sleep, as shown in the configuration of FIG. 69C. As shown
in FIG. 69D, in the Head position/movements monitoring
configuration, information about position and movements of the head
during sleep is acquired in order to identify possible, unconscious
abnormal positions/movements during sleep. An additional mode or
function may include (5) Audio streaming. The garment-embedded
earbuds may provide, if requested by the user, music or acoustic
stimulation as a sleep aid.
[0189] When a feature or element is herein referred to as being
"on" another feature or element, it can be directly on the other
feature or element or intervening features and/or elements may also
be present. In contrast, when a feature or element is referred to
as being "directly on" another feature or element, there are no
intervening features or elements present. It will also be
understood that, when a feature or element is referred to as being
"connected", "attached" or "coupled" to another feature or element,
it can be directly connected, attached or coupled to the other
feature or element or intervening features or elements may be
present. In contrast, when a feature or element is referred to as
being "directly connected", "directly attached" or "directly
coupled" to another feature or element, there are no intervening
features or elements present. Although described or shown with
respect to one embodiment, the features and elements so described
or shown can apply to other embodiments. It will also be
appreciated by those of skill in the art that references to a
structure or feature that is disposed "adjacent" another feature
may have portions that overlap or underlie the adjacent
feature.
[0190] Terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. For example, as used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, steps, operations, elements, and/or components, but do
not preclude the presence or addition of one or more other
features, steps, operations, elements, components, and/or groups
thereof. As used herein, the term "and/or" includes any and all
combinations of one or more of the associated listed items and may
be abbreviated as "/".
[0191] Spatially relative terms, such as "under", "below", "lower",
"over", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if a device in the figures is inverted, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus, the
exemplary term "under" can encompass both an orientation of over
and under. The device may be otherwise oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly. Similarly, the terms
"upwardly", "downwardly", "vertical", "horizontal" and the like are
used herein for the purpose of explanation only unless specifically
indicated otherwise.
[0192] Although the terms "first" and "second" may be used herein
to describe various features/elements (including steps), these
features/elements should not be limited by these terms, unless the
context indicates otherwise. These terms may be used to distinguish
one feature/element from another feature/element. Thus, a first
feature/element discussed below could be termed a second
feature/element, and similarly, a second feature/element discussed
below could be termed a first feature/element without departing
from the teachings of the present invention.
[0193] Throughout this specification and the claims which follow,
unless the context requires otherwise, the word "comprise", and
variations such as "comprises" and "comprising" means various
components can be co-jointly employed in the methods and articles
(e.g., compositions and apparatuses including device and methods).
For example, the term "comprising" will be understood to imply the
inclusion of any stated elements or steps but not the exclusion of
any other elements or steps.
[0194] In general, any of the apparatuses and methods described
herein should be understood to be inclusive, but all or a sub-set
of the components and/or steps may alternatively be exclusive, and
may be expressed as "consisting of" or alternatively "consisting
essentially of" the various components, steps, sub-components or
sub-steps.
[0195] As used herein in the specification and claims, including as
used in the examples and unless otherwise expressly specified, all
numbers may be read as if prefaced by the word "about" or
"approximately," even if the term does not expressly appear. The
phrase "about" or "approximately" may be used when describing
magnitude and/or position to indicate that the value and/or
position described is within a reasonable expected range of values
and/or positions. For example, a numeric value may have a value
that is +/-0.1% of the stated value (or range of values), +/-1% of
the stated value (or range of values), +/-2% of the stated value
(or range of values), +/-5% of the stated value (or range of
values), +/-10% of the stated value (or range of values), etc. Any
numerical values given herein should also be understood to include
about or approximately that value, unless the context indicates
otherwise. For example, if the value "10" is disclosed, then "about
10" is also disclosed. Any numerical range recited herein is
intended to include all sub-ranges subsumed therein. It is also
understood that when a value is disclosed that "less than or equal
to" the value, "greater than or equal to the value" and possible
ranges between values are also disclosed, as appropriately
understood by the skilled artisan. For example, if the value "X" is
disclosed the "less than or equal to X" as well as "greater than or
equal to X" (e.g., where X is a numerical value) is also disclosed.
It is also understood that the throughout the application, data is
provided in a number of different formats, and that this data,
represents endpoints and starting points, and ranges for any
combination of the data points. For example, if a particular data
point "10" and a particular data point "15" are disclosed, it is
understood that greater than, greater than or equal to, less than,
less than or equal to, and equal to 10 and 15 are considered
disclosed as well as between 10 and 15. It is also understood that
each unit between two particular units are also disclosed. For
example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are
also disclosed.
[0196] Although various illustrative embodiments are described
above, any of a number of changes may be made to various
embodiments without departing from the scope of the invention as
described by the claims. For example, the order in which various
described method steps are performed may often be changed in
alternative embodiments, and in other alternative embodiments one
or more method steps may be skipped altogether. Optional features
of various device and system embodiments may be included in some
embodiments and not in others. Therefore, the foregoing description
is provided primarily for exemplary purposes and should not be
interpreted to limit the scope of the invention as it is set forth
in the claims.
[0197] The examples and illustrations included herein show, by way
of illustration and not of limitation, specific embodiments in
which the subject matter may be practiced. As mentioned, other
embodiments may be utilized and derived there from, such that
structural and logical substitutions and changes may be made
without departing from the scope of this disclosure. Such
embodiments of the inventive subject matter may be referred to
herein individually or collectively by the term "invention" merely
for convenience and without intending to voluntarily limit the
scope of this application to any single invention or inventive
concept, if more than one is, in fact, disclosed. Thus, although
specific embodiments have been illustrated and described herein,
any arrangement calculated to achieve the same purpose may be
substituted for the specific embodiments shown. This disclosure is
intended to cover any and all adaptations or variations of various
embodiments. Combinations of the above embodiments, and other
embodiments not specifically described herein, will be apparent to
those of skill in the art upon reviewing the above description.
* * * * *