WO2017021719A1

WO2017021719A1 - Printed system yarns

Info

Publication number: WO2017021719A1
Application number: PCT/GB2016/052362
Authority: WO
Inventors: Brian NEWBY; Mark Pedley
Original assignee: Brighter Futures Partnership Limited
Priority date: 2015-07-31
Filing date: 2016-07-29
Publication date: 2017-02-09
Also published as: GB201513612D0

Abstract

The present invention relates to printed system yarns. More particularly, the present invention relates to yarns within which circuitry is provided. The present invention seeks to provide a yarn (25) comprising integrated electronics (10) to allow various or specific functionality to be provided by the yarn. Where the yarn is incorporated into a product for end-users, such as garments for example, the functionality can be provided for that product or integrated as part of the functionality of that product.

Description

PRINTED SYSTEM YARNS

Field of the Invention The present invention relates to printed system yarns. More particularly, the present invention relates to yarns within which circuitry is provided.

Background to the Invention The materials or products that are presently marketed as "smart textiles" or

"smart clothing" typically incorporate or integrate conventional hard form electronics within garment structures.

More advanced implementations of "smart clothing" use "textile" sensors, which may be formed using conductive inks printed on to textiles. Textile sensors can be knitted or woven and integrated into garments. The data collected by these textile sensors can be captured by electronics that may also be integrated within the garment during manufacture of the garment, or may be added separately after the textile has been manufactured. The entire system can include sensors, control electronics, conductive pathways, memory and data transmission provided as discrete components that are combined to enable the desired functionality of the system.

Current technology and consumer trends are driving adoption of smart clothing, however significant barriers remain in terms of connecting multiple components robustly and providing the sensors and electronics required for the desired functionalities at the sizes required to deliver an unobtrusive solution to end-user consumers.

Weaknesses in current textile sensor approaches include the problems of fracturing at the joins between components, along with the integration of varying fibres and connectivity of electronics to sensor pathways (be those of fibre, wire or other conductive materials). The dimensions and form factor of existing microprocessors, batteries and enclosures can create points of conflict and wear when integrated within softer material substrates.

These issues are limiting emerging market applications.

Summary of the Invention

The present invention seeks to provide a yarn comprising integrated electronics to allow various or specific functionality to be provided by the yarn. Where the yarn is incorporated into a product for end-users, such as garments for example, the functionality can be provided for that product or integrated as part of the functionality of that product.

According to a first aspect, there is provided an independently functional fibre for use in a yarn, the fibre comprising: a substrate material; and electronic circuitry provided onto or within the substrate, forming a core; wherein the electronic circuitry comprises one or a sequence of contiguous integrated functional elements throughout the core.

By providing circuitry onto or within a substrate, which comprises part of a fibre, a yarn can be created which is able to perform tasks of interest and/or use to a user.

Optionally, the substrate is in the form of an elongate and/or substantially continuous member.

Conventionally, fibres to be formed into yarns are in the form of an elongated, continuous shape. In order to provide a substrate which is operable to form part of such a fibre, the substrate too may be of a similar shape.

Optionally, the core comprises a substantially constant cross section and/or a single or substantially repeating sequence of contiguous integrated functional elements.

Optionally the core comprises a substantially repeating cross section and/or a single or substantially repeating sequence of contiguous integrated functional elements.

For ease of manufacture of the fibre, and consistency when developing the fibre into a yarn, it can be beneficial for the cross section of the core to remain substantially constant. However if such a core does not suit the needs of the individual fibre, or yarn for which the fibre may eventually be used, a repeating core cross section can reduce complexity and errors during manufacture. By providing a single or substantially repeating sequence of contiguous integrated functional elements, substantially continuous manufacturing of the fibre can be possible.

Optionally, the cross section comprises a circular, rectangular, complex, square, ribbon, ring-shaped, elliptical, star, lattice and/or tubular shape.

Optionally, the cross section is operable to affect the physical, chemical, and/or optical functionality of the core.

Optionally, the functional elements may comprise one or more of: connective electronic conducting pathways; sensors; memory; computer processing; communication modules; aerials; chemical substance delivery units; electro active units; energy harvesting units; and/or power storage units.

By having, for example, a rectangular cross-section, the costs associated with the substrate can be reduced, as a rectangular cross-sectioned substrate can be relatively cheap to manufacture. However this is not always optimal, as the area upon which electronic circuitry can be placed is limited, especially given the physical constraints on the size of a fibre to be woven into a yarn to eventually be incorporated into a fabric. With this in mind, the substrate can be of a variety of cross-sections to enable specific functionality, depending on desired end-use of the fibre, such as a circular, rectangular, complex, square, ribbon, ring-shaped, elliptical, star, lattice and/or tubular shaped cross-section. For the same diameter fibre, a greater surface area of substrate can be offered depending on the cross-section chosen, for example thereby affording a balance between internal and external surface areas and surface area upon which electronic circuitry can be placed. The substrate upon which the circuitry is adhered may be of a rectangular cross-section initially, and then subsequently rolled or furled into a coating which itself is then twisted, textured, rolled, furled, blended or merged with other fibres. Some structures of the substrate can enable functionality, for example a lattice structure can enable flexibility or deformation of the core to enable the core to function as a sensor (for example to measure piezo electric changes during deformation of a lattice structure). Some structures of the substrate can increase or decrease the strength of the core. A range of functionalities provides the fibre with a broader appeal and a greater range of potential abilities.

Optionally, the functional elements are flexible in a minimum of one dimension.

Providing functional elements which are flexible in one or more dimensions allows for a flexible fibre to be produced as a result. A flexible fibre may therefore be formed into a flexible yarn, which is more versatile in the products which can be produced using that yarn and also more resistant to damage during use. Alternatively, the functional elements can be flexible in two or more dimensions to achieve a similar effect.

Optionally, specific functions of the functional elements are dispersed along the length of the core for optimum performance related to the specific application.

Some parts of the functional elements may be more useful located in a certain part of a fibre. For example, if a sensor to measure heart rate is included in a fibre, then that sensor is only necessary within a certain region of the fibre. If the fibre is formed into a yarn, which is then developed into an article of clothing, a heart rate sensor need only be provided in the area surrounding the heart of a wearer of that article. The functional elements may therefore be more focused on a particular region, and potentially not receive the same levels of conflicting interference from other regions.

Optionally, the substrate material is operable to undergo a physical, chemical and/or optical change on the reception of one or more external stimuli. By undergoing a physical, chemical and/or optical change on the reception of one or more external stimuli, the substrate material may increase its resilience following an impact. The substrate material may also become more versatile in the applications for which it may be used, or provide a change following a stimulus even when power is not supplied to the fibre. For example, if the substrate is operable to change colour on contact with an acidic material, then such a colour change may provide useful information without the need for an external power source.

Optionally, the fibre further comprises a known and regular degree of twist per unit length, where the twist is operable to affect the physical, chemical, and/or optical functionality of the core.

Optionally, fibre comprising the known and regular degree of twist per unit length is operable to substantially encapsulate the core.

Providing a degree of twist per unit length can provide the fibre with a number of beneficial or useful properties. For example, by providing a twist in the fibre, or encapsulating the core within a twisted fibre, the resilience of the fibre and/or the core can be enhanced in the case of a sudden impact and/or the core can be located centrally to the fibre with the resulting protective benefits (especially where the twisted fibre is then optionally coated to provide a further layer of protection, for example with a plastic layer or layer of other material).

According to a second aspect, there is provided a fibre for use in a yarn, the fibre comprising; a substrate; and electronic circuitry provided on or within the substrate, forming a core.

Providing a fibre upon which circuitry is provided provides for flexibility in the configuration of yarns to perform various functions using the circuitry.

Optionally, a coating is formed around the core.

By enclosing a coating around electronic circuitry provided upon a substrate, a fibre can be produced which is capable of aiding with the performance of many different functions. These functions can include the incorporation of a sensing mechanism, a power source, or an antenna.

Optionally, the coating is degradable, optionally wherein the coating is degradable in response to external stimuli.

In some instances the coating can be degradable over a predetermined time period, where the predetermined time period is set during manufacture as appropriate to the application. For example, chemical or airborne stimuli can react with the coating to allow changes to be registered by the electronics as necessary, which itself can then create a reaction to or upon the fibre or yarn or material incorporating the fibre. Optionally, electronic circuitry is provided upon the substrate by printing the electronic circuitry upon the substrate.

The printing of electronic circuitry can offer a cheap and reliable method of bonding, layering or producing electronic circuitry upon a substrate. It can also offer quick prototyping of new arrangements of electronic circuitry before being put into mass production. Circuitry may be printed or formed on the substrate by using conductive or reactive inks, drawn metals, light or other etching techniques, X-ray, soldering, sealing, fusing, embossed, temperature burned or joining techniques.

Optionally, the core is produced by one or more of: printing; growing as a nanostructure; etching or the like, chemical, physical, or biological deposition; and/or chemical; physical, or biological ablation.

Optionally, the fibre is operable to form one or more of: a power source; capacitor; or super capacitor.

Optionally, the power source, capacitor, or super capacitor is an organic power source.

Optionally, the power source, capacitor, or super capacitor is integrated.

Use of other manufacturing methods to produce the substrate and/or core can mean that the substrate and/or core has a complex cross-section, for example the substrate and/or core can be printed using 3D printing or, alternatively, grown for example as a nano-structured material. Such printed or grown substrates and/or cores can have a unique or complex cross-section that enables certain printed system fibre functionality, for example forming micro-tubes that can contain a central release agent or agents, optionally which can be re-charged or re-filled for example during washing, or alternatively forming or containing required components for example an integral battery or organic battery, or capacitor or super capacitor. Such components can provide an electrical current to power any functional elements which comprise the fibre. If such a power source is integrated, then the power source cannot be lost or misplaced, which may impair the use of any functional elements which comprise the fibre.

Optionally, the fibre can comprise at least one sensor provided by the electronic circuitry provided upon the substrate.

By incorporating a sensor within the electronic circuitry provided upon the substrate, additional functionality can be performed by the fibre and therefore the yarn and/or fabric into which the fibre is eventually incorporated. The value of the fibre can be increased from the additional functionality, and any users of the fabric could benefit from the data collected by the sensors. Optionally, the electronic circuitry provided upon the substrate is operable to recognise change of state.

By recognising change of state, for example from a liquid to a gas or where a certain threshold (e.g. temperature, pressure) is reached or when liquid or a specific gas is detected, the sensory capacities of the fibre are increased. An alert could be sounded, for example, if liquid were detected where previously only gas was present. Useful information could therefore be provided in the case of an emergency, or if a potentially damaging impact to the fibre was detected. The fibre can also actively release certain chemical, biochemical or biological agents in response to detected inputs or state changes. These inputs may be from direct contact between the fibre and another object or body, or inputs received from changes related to the local environment, or inputs received from other sources or sensors. The release may be timed to occur when an input threshold is breached, after a set period of time, at a pre set time or at varying intervals. The release may be continuous, or dependant on the continued breaching of the threshold levels.

Optionally, any data collected by the fibre is transmitted to a remote device.

Optionally, electronic circuitry provided upon the substrate is operable to act as an antenna to send and/or receive radio-frequency signals.

Optionally, data is received from a remote device.

By transmitting any data collected by the fibre, more extensive data analysis can be performed, allowing for useful information to be gathered. Data can also be transmitted to other devices within a garment or to nearby or remote devices. By sending and/or receiving radio-frequency signals, data can be more easily transmitted between the fibre and an outside source. Data receipt or transmission can provide additional functionality to the device. For example, a fibre can be configured to be read using a device using any of the RFID, NFC, Zigbee Bluetooth or other communication protocols.

Optionally, the fibre can further comprise a battery, optionally wherein the battery provides either alternating or direct current to the electronic circuitry.

Optionally the fibre can comprise a power generation means.

A power source is required when any electronic device is in operation. Conventionally, batteries are used to store power, which can then be released when required. Fibres comprising a battery offer a less bulky solution to providing mobile power to the electronic components than transporting and connecting external batteries to the fibre. By incorporating a power generation means into a fibre, the electronics can be powered and/or the batteries recharged without the need for replacement or external charging means. The electronic functionality within the fibres can therefore be used for longer continuously. The power generated may be sourced from deformation or extension of the substrate itself, or from another source which the fibre is exposed to such as strain, light, thermal, displacement, motion, radio frequency, electrical input, infrared activity, solar, chemical, piezo, noise, or moisture. The fibres can be self- powering or can be operable to receive power from an outside or external source, such as through induction. Power can be generated or used from a combination of these sources, for example from a solar photovoltaic source during the day and harvested kinetic energy and stored power from a battery during the night.

Optionally, the fibre is any or all of: flexible and extendable.

By ensuring that the fibre is flexible and/or extendable, the opportunities to use the fibre increase. For example, for a fibre to be used as part of a fabric for clothing, a level of flexibility would be advantageous. Similarly, an extendable nature to the fibre could provide a degree of robustness and recovery, if pressure were to be applied on the fibre it could stretch without becoming permanently damaged.

Optionally, the electronic circuitry is operable to receive or execute computer code, optionally wherein the fibre is operable to receive computer code only once.

Optionally the electronic circuitry is operable to perform a pre-determined functionality at least periodically.

By including a computing device or logic within the electronic circuitry within the fibre, additional functionality of the fibre can be obtained. The function for which the electronic circuitry has been programmed can be changed if the computer or logic is programmable. The function can be fixed once and therefore the fibre will perform the same function throughout the useable lifespan of the computer or logic. Alternatively, the reprogramming of, updating of, or using machine learning on the computer code can enable multiple applications, and this updating or reprogramming can be brought about by a state change or in response to a trigger or activity (e.g. induction).

Optionally the electronic circuitry is formed integrally with the substrate.

By forming the circuitry and the substrate integrally, more complex fibres can be provided which can enable either flexibility of function, design and/or construction.

Optionally, the electronic circuitry is formed onto or within the substrate in a plurality of layers.

Layers of circuitry can allow for more efficient packaging, so as to fit greater functionality within a more confined area. Optionally, an outer face of the fibre is operable to provide connectivity to at least other fibres.

Connectivity via an outer face of the fibre can allow for easier and more reliable connectivity to other surrounding fibres. The reliability of any functional elements which rely on a connection with other surrounding fibres can therefore potentially be improved.

Optionally, one or more parameters of the one or more functional elements are set during manufacture, and cannot be altered.

Optionally, one or more parameters of the one or more functional elements are set after manufacture, and cannot be altered.

Optionally, one or more parameters of the one or more functional elements are set after manufacture, and are operable to be changed at a subsequent time.

Depending on the eventual purpose of the one or more functional elements, it can be beneficial to set one or more parameters during or after manufacture, which may or may not be operable to be altered once they have been set. For a simpler functional element, for ease of manufacture, increased reliability, and for convenience of an end user, a parameter may be set during manufacture and cannot be altered afterwards. Such a parameter may therefore be less likely to be amended with potentially adverse effects for the functional element. However some functional elements may be designed to be personalised by an end user, and therefore once they may have been mass- produced it would be appealing if a user could then alter one or more parameters based on their own personal preferences.

Optionally, a yarn can be formed comprising at least one fibre, wherein the fibre is formed into the yarn along with at least one other fibre.

By mixing multiple fibres into a single yarn, a number of benefits can be achieved. These can include increased functionality of the fibres, if they contain differing but complementary electronic components, or increased durability of the fibres if the materials of any accompanying fibres are chosen for that quality.

Optionally, an article can be formed from the yarn or the fibre.

By incorporating a yarn or fibre into an article, for example an item of clothing, the wearer can experience a number of benefits. Important diagnostic information can be sensed and transmitted, appliances can be charged from stored power within the item or clothing, or useful information can be transmitted to the wearer. Subsequently, the yarn can be used in the manufacturing of woven, knitted, roping, embroidery, crochet or other manufacturing techniques, or incorporated into non-woven substrates as part of the manufacturing protocols of the non-woven materials. Optionally, the yarn or article comprises interconnections formed between multiple fibres within the same said yarn or article.

Optionally, the yarn or article comprises fibres operable to execute computer code in parallel.

By providing interconnections between multiple fibres within the same yarn or article, functionality within the yarn or article can be increased, as multiple fibres containing electronic components can be in contact and working alongside one another. This can also provide a degree of redundancy if required, so the damaging of a particular fibre does not prevent the use of the yarn or article. Parallel processing can also be a result of multiple fibres being interconnected, if more than one fibre houses a computer. The interconnections can be direct contact connections between portions of the fibres or at multiple points along the fibres or can be indirect connections, for example inductive. Where an interconnection link between fibres/yarns is inductive, the interconnections can be between fibres and/or yarns spaced a suitable distance apart and this distance may vary over the length of the fibres or only a portion of each or both fibres may be indirectly connected. For example, where sensors are provided at a set distance apart from each other, for example throughout a garment made up from the fibres and/or yarns, this can enable different uses of the fibres and/or yarns (for example, to detect the rate of diffusion of a signal, or a trigger to release an agent).

According to another aspect, there is provided a method of manufacturing the fibre and/or yarn according to any preceding claim.

By forming a fibre of the type disclosed in this application, a fibre can be produced which is capable of aiding with the performance of many different functions. As described above, these functions can include the incorporation of a sensing mechanism, a power source, or an antenna. There also exist a number of medical uses regarding the sensor mechanisms.

Optionally, the electronic circuitry is are provided on the substrate in a continuous manner.

By providing the electronic circuitry on to the substrate continuously, for example by printing the circuitry on the substrate, manufacturing can be more efficient or can output fibres or yarns continuously.

Optionally, the substrate is produced in a continuous manner.

By producing the substrate in a continuous manner, which can be similar or the same as the manner used for the production of synthetic fibres for example, manufacturing can be more efficient or can output fibres or yarns continuously.

Optionally, there is provided a machine-readable map, or machine-readable instructions, configured to enable a printing or other automated manufacturing process to manufacture the fibre of any preceding claim.

Providing some format of configuration file for example for 3D printing the apparatus, or portions of the apparatus, allows for convenient manufacture of the fibre. Remote manufacture could also take place, so the point of production of the fibre is less restricted.

Brief Description of the Drawings Specific embodiments will now be described, by way of example only and with reference to the accompanying drawings having like-reference numerals, in which:

Figure 1 illustrates the cross section of an embodiment of the apparatus, showing a yarn incorporating a printed system fibre, where the printed system fibre contains a substrate of a substantially rectangular cross-section;

Figure 2 illustrates the cross section of an alternative embodiment of the apparatus, showing a yarn incorporating a printed system fibre, where the printed system fibre contains a substrate of a substantially horseshoe-shaped cross section;

Figure 3 illustrates the cross section of a further alternative embodiment of the apparatus, showing a yarn containing a mix of standard fibres, treated or conditioned fibres and/or printed system fibres;

Figure 4 illustrates a method of manufacture of the printed system yarn; and Figure 5 illustrates an alternative method of manufacture of the printed system yarn. Specific Description

A yarn can be defined as a continuous length of interlocked fibres. A fibre on which electronic circuitry or components are provided, for the purposes of this specification, shall be referred to as a printed system fibre. For the purposes of this specification, the term printed system yarn shall be used to describe a yarn which contains at least one printed system fibre, preferably as the central fibre, around which further fibres are provided.

The printed system fibre can be formed by either printing, or by another manufacturing method, which of itself or as a result of a combination of manufacturing techniques applies the electronics onto the surface of a fibre or fibre substrate. Optionally, the fibres may subsequently be encapsulated to protect the electronics in day-to-day usage and protect against damage. The electronics can be provided on or within the fibre or fibre substrate as a self-contained system, component, or series of components and may have a form which is substantially linear, for example extended in one dimension relative to other dimensions, such that the form factor of the electronics, components or system can be provided in series along the substrate or fibre.

Referring to Figures 1 to 5, several embodiments of a printed system yarn will now be described in more detail.

Figure 1 illustrates the cross section of a printed system yarn 25 according to an embodiment.

The printed system fibre 10 comprises a receiving substrate 1 upon which electronic circuitry is incorporated. The receiving substrate 1 can be a variety of shapes, including a length of suitable material of a flat, ribbon, circular ,oval or other cross- sectional profile. In this embodiment, the substrate is of a substantially flat, rectangular cross-sectional profile. The receiving substrate 1 allows the integration of circuitry and its components on to the substrate 1. The circuitry and components can be created in a linear manner, in contrast to the rectangular, square, round or other shapes commonly found in standard printed circuit board and application-specific integrated circuit forms. The printed system fibre 10 can be produced by encapsulating the substrate 1 (upon which circuitry and/or components are integrated) within a covering material 8. The substrate 1 (upon which circuitry and/or components are integrated) and covering material 8 are then combined to form a printed system fibre 10. Surrounding the printed system fibre 10 with other fibres 5 can provide protection for the printed system fibre 10, thereby increasing the durability of the fabric into which the yarn 25 is eventually incorporated. The other fibres 5 may be conventional fibres or other types of fibre, including other printed system fibres 10.

Referring to Figure 2, a cross section of an alternative embodiment of the apparatus is shown, where the printed system fibre 12 contains a substrate 15 of a substantially horseshoe-shaped cross section.

In this alternative embodiment, electronic circuitry and/or components have been integrated onto substrate 15, as described in relation to substrate 1 above. Other fibres 5 have been arranged to surround the printed system fibre 12, again as described above in relation to the embodiment in Figure 1 , forming a printed system yarn 27.

Referring to Figure 3, a cross section of a further alternative embodiment of the apparatus is shown, containing a mix of standard fibres 5, treated or conditioned fibres 20 and printed system fibres 10.

In this embodiment, the printed system fibres 10 are similar to those described above in relation to Figure 1 , however the fibres 10 can take any of the forms outlined in this specification.

The yarn 35 arrangement can provide additional benefits, for example increased strength and durability of the fabric into which the yarn 35 is eventually incorporated. The arrangement can also include a plurality of printed system fibres 10, wherein a different electronic arrangement can be integrated into each of the printed system fibres 10, thereby providing them each with a different function. This can offer additional functionality within the same yarn 35, for example: a level of parallel processing in the case of a computer system; or some redundancy in the case of duplicated printed system fibres 10. Where redundancy is preferred, if one printed system fibre 10 were to be damaged, another could perform the same function with no interruption to the user. Redundancy can also be intentionally absent, for example where a lack of functionality of a particular circuit can be used as an indicator that an object has been damaged or tampered with. The mode of action of any sensors present in the assembly can also be facilitated, with power and data storage requirements met by the one or more printed system fibres 10 present in the yarn 35, or in the fabric as a whole. The numbers and positioning of the treated fibres 20 may be chosen to advantageously impact the effect of the treatment or conditioning on the mode of action on the yarn 35 as a whole.

The fibres 5, 20 adjacent the printed system fibre 10 may be utilised to generate power for the printed system fibre 10. Such generation could include optical, heat, kinetic, deformation, chemical, electrochemical, or magnetic means.

In another embodiment, the fibres 5, 20 adjacent the printed system fibre 10 may be utilised as an antenna. The printed system fibre 10 may be designed so as to interact directly with other adjacent printed system fibres 10.

Referring to Figure 4, a method of manufacture of a printed system yarn 25 is shown.

Electronic circuitry is integrated into a base 30, thereby forming a substrate 1. The printed system fibre 10 can be produced by encapsulating the substrate 1 within a covering material 8. The substrate 1 and covering material 8 are then combined to form a fibre, creating the printed system fibre 10. The printed system fibre 10 can then be surrounded by standard fibres 5 to create the overall yarn 25, as shown in Figure 1.

Figure 5 shows a similar process to that shown in Figure 4.

In contrast to the process shown in Figure 4, the process in Figure 5 shows a base 30 that is formed into a substantially horseshoe shape, generating a horseshoe- shaped substrate 15. The printed system fibre 12 can be produced by encapsulating the substrate 15 within a covering material 8. The substrate 15 and covering material 8 are then combined to form a fibre, creating the printed system fibre 12. As shown in Figure 2, such a printed system fibre 12 can then be surrounded by standard fibres 5 to create the printed system yarn 27.

The substrates 1 , 15 can be designed such that they incorporate the elements and circuitry required for an antenna. The antenna can be used to transmit information from the printed system fibre 10, for example any information captured from in-built sensing elements if present. This antenna can be optimized for individual in-use applications. The antenna can be provided to perform two-way communication, which can therefore allow for transmission but also receiving information, and in some embodiments the printed system yarn can acquire certain sensor input(s) or information from its locality and respond accordingly.

The substrates 1 , 15 may be designed such that they incorporate elements and circuitry required to interact directly with other elements within the third party objects. These other elements may be other printed system fibres 10 or other conductive elements which may or may not be fibres. These other elements may take the form of an antenna, or methods of transmitting or producing power required by the printed system yarn 25 wherein the printed system yarn 25 is fully flexible and pliable to ensure that it may be used in various manufacturing methods. Such methods may include standard fabric manufacture, such as being looped into a warp or weft knitted loop, or interlaced into a woven manner or interlocked in an embroidered or crocheted manner. The printed system yarn 25 may also be laid into or upon a non-woven substrate. The printed system yarn 25 circuitry and antennas may remain a one-piece form factor, requiring no other connector or connection method to perform.

The printed system fibre 10 may be a result of extrusion or another method which may manufacture and inject the polymer or mix of fibre materials and funnel them to a point where the antennas and circuitry components can be added in sequence as the substrate 1 exits the funnel onto a flat plane. The substrate 1 is then run through a broader funnel opening to be rolled or furled into a fine extended linear manner for further twisting or embodying, as the application requires.

An alternative to printing the circuitry, components or electronics on to the substrate is possible and can be fabricated, moulded or formed as a complete component (inclusive of its sub-components) or as sub-components which can then be fused, bonded, glued or otherwise attached to the core substrate fibre. An alternative manufacture method comprises reversing the funnel action, thereby injecting a fine polymer or other suitable chemical through a fine nozzle and onto a flat plane upon which the yarn circuitry is married to the polymer, allowing the polymer to engulf or create a sheath around the substrate 1 in an elongated linear manner.

Printed system yarns 25, 27, 35 may be considered as having one of four discrete modes of action:

(1 ) Passive - where elements of the circuitry contain a unique identifying code which is fixed at the point of manufacture;

(2) Active - where elements of the circuitry contain a unique identifying code

which is programmable at the point of sale or use;

(3) Sensing - where elements of the circuitry capture a state change of or within the structure of the yarn, corresponding to external stimuli which is imposed upon it; or

(4) Interactive - where state changes captured by elements of the circuitry

integrated within the structure of the yarn result in a change in the physical property of the yarn. As appropriate, the integrated circuitry may also include the ability to self-power, record and transmit a state change of the fibre and/or to record a change of influence such as stretch, compression, presence of fluid, temperature, light, sound, presence of electrical properties, or friction upon the fibre.

The power circuitry, including a microcontroller, can provide energy to activate or register a material change. The change circuitry, including a mechanism which changes the state between on & off, can comprise a transistor into which the change data can be stored, the communications circuitry from which a power reader may collect the data, and the antennas required to wirelessly connect the circuit board to the power reader. This circuitry can be integrated as one complete module, fibre or yarn.

The entire assembly can be encapsulated, sealed, or protected using other non- permeable membranes sufficient that chemicals, fluids and moisture cannot adversely affect the control module unless external ingress is specifically required to activate the sensing elements.

The assembly plus the encapsulation and incorporation within a printed system yarn 25 together can represent no more than a specified maximum increase (+/- 5 %) in the overall girth of an existing standard garment yarn 5. A minimal increase in the girth of the finished printed system yarn 25 can avoid causing any obstruction when used in dying, protection or colour processing, and when the finished printed system yarn 25 is deployed using established and operational manufacturing methods such as sewing, weaving, knitting, embroidery or even non-woven manufacturing techniques. The manufactured printed system yarn 25 can also retain mechanical properties with respect to deformation and elasticity which are broadly identical to standard manufactured yarns if they are to be utilized in garments or fabrics.

The specific use of printed system yarns 25 and their integration into materials, fabrics and composites would be determined by the application. The emergence of this technology can mitigate the problems and challenges currently experienced when using conductive yarns to create switches or sensors and can facilitate the connectivity between sensors and electronics.

Currently, placing of sensory printed system yarn 25 with pre-designated components such as sensors on a living body is undertaken as a separate task to wearing a garment, and is a task to be performed by trained and skilled operators or technicians. A linear sensor that is integrated into a printed system fibre can be targeted and meticulously placed within a yarn, therefore within a garment or object, so as to achieve the purposes for which the sensor is to be applied without any requirement to spill into other surrounding or peripheral areas of the area which is to be sensed. This increases the reliability and accuracy of a switch, sensor or monitor included in such a printed system fibre 10 as it captures the best quality and most useful data as required by the application.

A further application of embodiments of the printed system yarn 25 described above can include a wide range of applications such as: security tagging; tracking; and anti-counterfeiting uses. Many such systems are based on the adoption and reading of unique codes which may be visible or electronic. Current electronic tags may be located in a single site on the object to be tracked or tagged, which makes them easier to circumvent, replace or otherwise subvert. As a printed system yarn 25 can contain a number of discrete coded units within a particular length, such yarn(s) 25 could be seamlessly embedded within a variety of objects, and at a variety of locations. If the location(s) of the printed system yarn(s) 25 became known it would be possible to quickly relocate to new locations within the object in future manufacturing. The security of the object could therefore be increased or made more pervasive throughout the object, making tampering and counterfeiting more difficult. Current sensory techniques exist for monitoring impact forces within objects which may show no outward sign of deformation, but whose structural integrity may be compromised after exposure to forces of a certain magnitude. Many objects, particularly those used in the construction industry, have very strict limits on the loads which can be applied before the object is no longer fit for purpose. The use of printed system yarns 25 according the embodiments described above can be used to provide a plurality of shock sensors that can be integrated into a highly flexible and small footprint substrate. A printed system yarn 25 can, for example, be embedded into the object directly during manufacture and sensor information can then be relayed actively or read via reader after a particular event. The impact and load history of an object can therefore be carefully recorded and monitored.

In some embodiments, the manufacturing process of the electronic components, fibre or yarn is a continuous uninterrupted process, for example such as printing or as otherwise described in this application, that produces a contiguous component or set of electronic components. For example, a series of sensor, processor, memory and power components can be produced in a series of components in sequence in the continuous inuninterrupted process. This can provide the advantage of avoiding the need to pick and place various electronic components and then interconnect these, by populating a fibre/yarn with the electronic components along the yarn in series as part of the continuous uninterrupted process.

Other applications for these new sensors may include: personal safety, identification of goods, tracking goods in logistics, illumination, energy and power accumulation, biomechanical or biometric data collection, temperature responses, light changes (natural or artificial), environment or chemical (solid, liquid, or gas) changes, activity and movement, distortion and deformation, strain, impact and pressure (negative or non-negative), sheer and friction, layering, immersion, containment and the collection of environmental measurements.

Any system feature as described herein may also be provided as a method feature, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to system aspects, and vice versa. Furthermore, any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination. It should also be appreciated that particular combinations of the various features described and defined in any aspects of the invention can be implemented and/or supplied and/or used independently.

Claims

An independently functional fibre for use in a yarn, the fibre comprising:

a substrate material; and

electronic circuitry provided onto or within the substrate, forming a core; wherein

the electronic circuitry comprises one or a sequence of contiguous integrated functional elements throughout the core.

A fibre according to claim 1 wherein the substrate is in the form of an elongate and/or substantially continuous member.

A fibre according to claim 1 or 2 wherein the core comprises a substantially constant cross section and/or a single or substantially repeating sequence of contiguous integrated functional elements.

A fibre according to any preceding claim wherein the core comprises a substantially repeating cross section and/or a single or substantially repeating sequence of contiguous integrated functional elements.

A fibre according to any preceding claim wherein the cross section comprises a circular, rectangular, complex, square, ribbon, ring-shaped, elliptical, star, lattice, and/or tubular shape.

A fibre according to any preceding claim wherein the cross section is operable to affect the physical, chemical, and/or optical functionality of the core.

A fibre according to any preceding claim wherein the functional elements may comprise one or more of: connective electronic conducting pathways; sensors; memory; computer processing; communication modules; aerials; chemical substance delivery units; electro active units; energy harvesting units; and/or power storage units.

A fibre according to any preceding claim wherein the functional elements are flexible in a minimum of one dimension.

9. A fibre according to any preceding claim wherein specific functions of the functional elements are dispersed along the length of the core for optimum performance related to the specific application.

10. A fibre according to any preceding claim wherein the substrate material is operable to undergo a physical, chemical and/or optical change on the reception of one or more external stimuli.

1 1 . A fibre according to any preceding claim further comprising a known and regular degree of twist per unit length, where the twist is operable to affect the physical, chemical, and/or optical functionality of the core.

12. A fibre according to claim 1 1 wherein the fibre comprising the known and regular degree of twist per unit length is operable to substantially encapsulate the core.

13. A fibre for use in a yarn, the fibre comprising;

a substrate; and

electronic circuitry provided on or within the substrate, forming a core.

14. A fibre according to any preceding claim further comprising a coating formed around the core.

15. A fibre according to any preceding claim wherein the coating is degradable, optionally wherein the coating is degradable in response to external stimuli.

16. The fibre according to any preceding claim wherein the electronic circuitry is provided upon the substrate by printing the electronic circuitry upon the substrate.

17. A fibre according to any preceding claim wherein the core is produced by one or more of: printing; growing as a nanostructure; etching or the like; chemical, physical, or biological deposition; and/or chemical; physical, or biological ablation.

18. A fibre according to any preceding claim operable to form one or more of: a power source; capacitor; or super capacitor.

19. A fibre according to any claim 18 wherein the power source, capacitor, or super capacitor is an organic power source.

20. A fibre according to any claim 18 or 19 wherein the power source, capacitor, or super capacitor is integrated.

21 . The fibre according to any preceding claim, further comprising at least one sensor provided by the electronic circuitry provided upon the substrate. 22. The fibre according to any preceding claim wherein the electronic circuitry provided upon the substrate is operable to recognise change of state.

23. The fibre according to any preceding claim wherein any data collected by the fibre is transmitted to a remote device.

24. The fibre according to any preceding claim further comprising electronic circuitry provided upon the substrate operable to act as an antenna to send and/or receive radio-frequency signals. 25. The fibre according to any preceding claim wherein data is received from a remote device.

26. The fibre according to any preceding claim further comprising a battery, optionally wherein the battery provides either alternating or direct current to the electronic circuitry.

27. The fibre according to any preceding claim further comprising power generation means. 28. The fibre according to any preceding claim wherein the fibre is any or all of: flexible and extendable.

29. The fibre according to any preceding claim wherein the electronic circuity is operable to receive or execute computer code, optionally wherein the fibre is operable to receive computer code only once.

30. The fibre according to any preceding claim wherein the electronic circuity is operable to perform a pre-determined functionality at least periodically.

31 . The fibre according to any preceding claim wherein the electronic circuitry is formed integrally with the substrate.

32. The fibre according to any preceding claim wherein the electronic circuitry is formed onto or within the substrate in a plurality of layers.

33. The fibre according to any preceding claim wherein an outer face of the fibre is operable to provide connectivity to at least other fibres.

34. A fibre according to any preceding claim wherein one or more parameters of the one or more functional elements are set during manufacture, and cannot be altered.

35. A fibre according to any preceding claim wherein one or more parameters of the one or more functional elements are set after manufacture, and cannot be altered.

36. A fibre according to any preceding claim wherein one or more parameters of the one or more functional elements are set after manufacture, and are operable to be changed at a subsequent time.

37. A yarn comprising at least one fibre according to any preceding claim, wherein the fibre is formed into the yarn along with at least one other fibre.

38. An article formed from the yarn or the fibre of any preceding claim.

39. The yarn or article of any preceding claim wherein interconnections are formed between multiple fibres within the same said yarn or article.

40. The yarn or article of any preceding claim having a plurality of fibres according to any of claims 1 to 36 wherein the fibres are operable to execute computer code in parallel.

41 . A method of manufacturing the fibre or yarn according to any preceding claim.

42. A method of manufacturing according to claim 41 , wherein the electronic circuitry is provided on the substrate in a continuous manner.

43. A method of manufacturing according to any of claims 41 or 42, wherein the substrate is produced in a continuous manner.

44. A method of manufacturing according to any of claims 41 to 43, wherein the manufacturing process is performed in a continuous uninterrupted process.

45. A method of manufacturing according to any of claims 41 to 44, wherein the manufacturing process is performed onto or within a core fibre in a continuous uninterrupted process.

46. A machine readable map, or machine readable instructions, configured to enable a printing or other automated manufacturing process to manufacture the fibre of any preceding claim.

47. An apparatus referred to and substantially described herein with reference to the accompanying drawings.

48. A method referred to and substantially herein described with reference to the accompanying drawings.