EP3719819A1

EP3719819A1 - Inductive components and methods of forming inductive components

Info

Publication number: EP3719819A1
Application number: EP19166782.3A
Authority: EP
Inventors: Ugo Sassi; Zoran Radivojevic; Philip DERRICK; Matteo BRUNA
Original assignee: Nokia Technologies Oy
Current assignee: Nokia Technologies Oy
Priority date: 2019-04-02
Filing date: 2019-04-02
Publication date: 2020-10-07

Abstract

An inductive component comprising: a substrate comprising a plurality of layers; magnetic material; and at least one coil of conductive thread wound through the substrate to mechanically interconnect the plurality of layers, wherein at least a portion of the at least one coil of conductive thread is located around at least a portion of the magnetic material.

Description

TECHNOLOGICAL FIELD

Examples of the present disclosure relate to inductive components and methods of forming inductive components. Some examples relate to inductive components and methods of forming inductive components for use in wearable electronic devices.

BACKGROUND

Wearable electronic devices comprise electronic components which can be integrated within the fabric of an article of clothing or strap or other suitable means. In examples, the electronic components need to be comfortable, water and sweat proof and washable.

BRIEF SUMMARY

According to various, but not necessarily all, embodiments there is provided an inductive component comprising:

a substrate comprising a plurality of layers;
magnetic material; and
at least one coil of conductive thread wound through the substrate to mechanically interconnect the plurality of layers, wherein at least a portion of the at least one coil of conductive thread is located around at least a portion of the magnetic material.

In some but not necessarily all examples, the conductive thread comprises an outer insulating layer.
In some but not necessarily all examples, the substrate comprises at least one magnetic material layer and the magnetic material comprises at least a portion of the at least one magnetic material layer.
In some but not necessarily all examples, at least a portion of the magnetic material comprises at least one magnetic strip and/or at least one magnetic fibre.
In some but not necessarily all examples, the substrate comprises a first non-magnetic, non-conductive layer and a second non-magnetic, non-conductive layer, and the first non-magnetic, non-conductive layer and the second non-magnetic, non-conductive layer are the outer layers of the substrate.
In some but not necessarily all examples, at least one of the layers is formed from fabric or textile.
In some but not necessarily all examples the inductive component comprises a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first coil and the second coil are configured to form a transformer.
In some but not necessarily all examples, the transformer comprises at least one of a shell type transformer and a core type transformer.
In some but not necessarily all examples, the inductive component comprises a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first and second coils are interlaced.
According to various, but not necessarily all, embodiments there is provided a wearable electronic device comprising an inductive component as described herein
According to various, but not necessarily all, embodiments there is provided a method of forming an inductive component comprising:

forming a substrate comprising a plurality of layers, the substrate comprising magnetic material; and
forming at least one coil of conductive thread wound through the substrate to mechanically interconnect the plurality of layers, wherein at least a portion of the at least one coil of conductive thread is located around at least a portion of the magnetic material.

In some but not necessarily all examples, the at least one coil of conductive thread is wound through the substrate using a curved needle.
In some but not necessarily all examples, the substrate comprises at least one magnetic material layer and the magnetic material comprises at least a portion of the at least one magnetic material layer.
In some but not necessarily all examples, at least one of the layers is formed from fabric or textile.
In some but not necessarily all examples, the method comprises forming at least one wearable electronic device comprising the inductive component within the wearable electronic device.
In some but not necessarily all examples the conductive thread comprises an outer insulating layer.
In some but not necessarily all examples, at least a portion of the magnetic material comprises at least one magnetic strip and/or at least one magnetic fibre.
In some but not necessarily all examples, the substrate comprises a first non-magnetic, non-conductive layer and a second non-magnetic, non-conductive layer, and the first non-magnetic, non-conductive layer and the second non-magnetic, non-conductive layer are the outer layers of the substrate.
In some but not necessarily all examples the inductive component comprises a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first coil and the second coil are configured to form a transformer.
In some but not necessarily all examples, the transformer comprises at least one of a shell type transformer and a core type transformer.
In some but not necessarily all examples, the inductive component comprises a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first and second coils are interlaced.
According to various, but not necessarily all, embodiments there is provided examples as claimed in the appended claims.

BRIEF DESCRIPTION

Some example embodiments will now be described with reference to the accompanying drawings in which:

FIG 1 shows an example embodiment of the subject matter described herein:
FIGS 2A and 2B show another example embodiment of the subject matter described herein;
FIGS 3A and 3B show another example embodiment of the subject matter described herein;
FIGS 4A and 4B show another example embodiment of the subject matter described herein;
FIGS 5A and 5B show another example embodiment of the subject matter described herein;
FIG 6 shows another example embodiment of the subject matter described herein;
FIGS 7A and 7B show another example embodiment of the subject matter described herein;
FIG 8 shows another example embodiment of the subject matter described herein; and
FIG 9 shows another example embodiment of the subject matter described herein.

DETAILED DESCRIPTION

Examples of the disclosure relate to an inductive component 10 and a method of forming an inductive component 10.
In examples, the inductive component 10 comprises a substrate 12 comprising a plurality of layers 14; magnetic material 16; and at least one coil of conductive thread 18 wound through the substrate 12 to mechanically interconnect the plurality of layers 14, wherein at least a portion of the at least one coil of conductive thread 18 is located around at least a portion of the magnetic material 16.
The inductive component 10 could be an inductor 54, a transformer 36, local booster, noise/interference filtering components, inductive chargers, resonators or any other suitable type of inductive component 10.
The use of one or more coils of conductive thread 18 wound through a multi-layer substrate 12 allows, for example, mechanical interconnection of flexible materials, such as fabric or textile, and at the same time having electronic functionality.
In examples, the substrate 12 can be formed from fabric or textile and the at least one coil of conductive thread 18 can be used to attach together, for example, different parts of a wearable electronic device 38 while at the same time providing electronic functionality.
Furthermore, the inductive component 10 can be small and lightweight and suitable for use within a wearable electronic device 38.
The inductive component 10 can be small enough and light enough so that a wearable electronic device 38 comprising the inductive component 10 is still comfortable for a subject to wear.
The inductive component 10 can be compact, comfortable, stretchable and washable allowing such an inductive component 10 to be used in wearable electronic devices 38.
Such an inductive component 10 can easily be sealed by encapsulation to provide further water and/or solvent agent resistance.
FIG 1 schematically illustrates an example of an inductive component 10.
Various features referred to in relation to FIG 1 can be found in the other figures. See, for example, FIGS 2A and 2B.
In FIG 1, the inductive component 10 comprises a substrate 12 comprising a plurality of layers 14, magnetic material 16 and at least one coil of conductive thread 18.
In the illustrated example, the at least one coil of conductive thread 18 is wound through the substrate 12 to mechanically interconnect the plurality of layers 14. In examples the at least one coil of conductive thread 18 can be considered to attach, connect, interlock, join, link, fix and/or tie the plurality of layers 14.
However, in examples the at least one coil of conductive thread can be applied to and/or located in the substrate 12 in any suitable way to interconnect the plurality of layers 14.
At least a portion of the at least one coil of conductive thread 18 is located around at least a portion of the magnetic material 16. This is schematically illustrated in the example of FIG 1 by the box representing the at least one coil of conductive thread 18 partially overlapping the box representing the magnetic material 16.
In examples at least a portion of the at least one coil of conductive thread 18 is located around the magnetic material 16. That is, in examples the magnetic material 16 can be located within the at least one coil of conductive thread 18.
The substrate 12 of the inductive component 10 can comprise any suitable number and/or type of layers 14. For example, the layers 14 of the substrate 12 can comprise any suitable combination of material or materials.
In examples the substrate 12 can be considered a magnetically enhanced substrate 12.
Additionally or alternatively the layers 14 of the substrate 12 can be formed of any suitable shapes and/or sizes including the same or different shapes and/or sizes.
In examples, the layers 14 can comprise any suitable material or materials, for example, any suitable flexible material and/or any suitable material for use in a wearable electronic garment 38.
In examples, at least one of the layers 14 is formed from fabric or textile. In some examples, all layers 14 of the substrate 12 are formed from fabric or textile.
According to some, but not necessarily all, examples the substrate 12 comprises a first non-magnetic, non-conductive layer 30 and a second non-magnetic, non-conductive layer 32, and wherein the first non-magnetic, non-conductive layer 30 and the second non-magnetic, non-conductive layer 32 are the outer layers of the substrate 12.
For example, the magnetic material 16 of the substrate 12 can be embedded between the two non-conductive, non-magnetic layers 30, 32.
Any suitable non-magnetic, non-conductive material can be used, for example any suitable material that does not electrically conduct electricity and does not become magnetised.
In examples, any suitable non-magnetic, non-conductive textile or fabric such as polyester, nylon, cotton, Lycra, bamboo, neoprene, rayon, acrylic, wool, silk and so on can be used.
In examples, the substrate 12 can comprise different portions of a garment 50 that are mechanically interconnected by the at least one coil of conductive thread 18. For example, a zip or other fastening means/fastener can be attached to another portion of a garment 50 by the at least one coil or conductive thread 18.
The magnetic material 16 can comprise any suitable magnetic material 16. For example, the magnetic material 16 can comprise any suitable magnetic material 16 to form a core of an inductive component 10. The magnetic material 16 can have any suitable shape, size and/or form.
Any suitable magnetic/ferromagnetic material can be used. For example, elements containing iron such as ferrites, elements of composites containing nickel, cobalt or rare earth metal and so on.
In examples, the substrate 12 comprises at least one magnetic material layer 24 and wherein the magnetic material 16 comprises at least a portion of the at least one magnetic material layer 24. See, for example, FIGS 2A, 2B, 4A, 4B, 5A, 5B.
The at least one magnetic material layer 24 can be a magnetic fabric or textile, for example, fabric or textile made of magnetic fibres, or a fabric or textile coated by a magnetic/ferromagnetic material or a magnetic/ferromagnetic ink dispersed on a non-conductive fabric or textile and so on.
Additionally or alternatively, the at least one magnetic material layer 24 can comprise/ be a thin magnetic sheet.
In some examples at least a portion of the magnetic material 16 comprises at least one magnetic strip 26 and/or at least one magnetic fibre 28. See, for example, FIGS 3A and 3B.
In examples a magnetic strip 2 and a magnetic fibre can differ in shape and/or size. For example, a magnetic fibre can be narrower than a magnetic strip.
In examples, the at least one coil of conductive thread 18 is wound through the substrate 12 comprising at least one magnetic material layer 24.
In such examples the portion of the at least one magnetic layer 24 located within the at least one coil of conductive thread 18 provides at least a portion of the magnetic material 16.
In some examples, the at least one coil of the conductive thread 18 is wound around at least one magnetic strip 26 and/or at least one magnetic fibre 28. In such examples, the magnetic strip(s) 26 and/or magnetic fibre(s) 28 provide at least a portion of the magnetic material 16.
In some examples, the substrate 12 can comprise both at least one magnetic material layer 24 and one or more magnetic strips 26 and/or one or more magnetic fibres 28. The at least one coil of conductive thread 18 can have any suitable form and/or shape and/or size. For example, the at least one coil of conductive thread 18 can have any suitable form and/or shape and/ or size to form a conductive part of an inductive component 10.
In examples the at least one coil of conductive thread 18 can comprise any suitable number and/or size and/or pattern of turns or loops. For example, the number of turns in the coil 18 can be determined or based on the functionality of the inductive component 10.
In examples the at least one coil of conductive thread 18 can be considered a spiral structure and/or helical structure and/or helix and/or spiral of conductive thread 18.
The at least one coil of conductive thread 18 is located through the substrate 12 to mechanically interconnect the plurality of layers 14 of the substrate 12.
In examples, at least some of the turns of the coil of conductive thread 18 pass through the layers 14 of a substrate 12 to mechanically interconnect the layers 14 of the substrate 12.
The conductive thread 20 can comprise any suitable material or materials.
In examples, the conductive thread 20 comprises an outer insulating layer 22. See, for example, FIGS 7A and 7B.
The use of an outer insulating later 22 on the conductive thread 20, for example, prevents electrical short circuit between adjacent conductive loops of the coil 18.
Furthermore, the use of an outer insulating layer 22 prevents, for example, the requirement of an extra coating or layer to insulate the inductive component 10, for example, when in contact with skin of a garment wearer.
The outer insulating layer 22 can also insulate the inductive component 10 from the external environment, protecting the component from environmental factors such as humidity, corrosion, oxidation and similar.
The inductive component 10 can comprise any suitable number of coils of conductive thread 18.
For example, the inductive component 10 can comprise a plurality of coils of conductive thread 18. In examples, the plurality of coils of conductive thread 18 can be the same or different.
In examples, the inductive component 10 comprises a first coil of a conductive thread 18a wound through the substrate 12 and a second coil of conductive thread 18b wound through the substrate 12, wherein the first coil 18a and the second coil 18a are configured to form a transformer 36.
In examples, the transformer 36 comprises at least one of a core type transformer 36a and a shell type transformer 36b.
See, for example, FIGS 4A, 4B, 5A and 5B.
In some, but not necessarily all, examples, the inductive component 10 comprises a first coil of conductive thread 18a wound through the substrate 12 and a second coil of conductive thread 18B wound through the substrate 12, wherein the first and second coils 18a, 18b are interlaced/interlocked.
See, for example, FIG 6.
In examples, any suitable number of conductive coils 18 can be interlaced/interlocked.
Accordingly, the inductive component 10 comprises one or more coils of a conductive thread 18 around magnetic material 16 which provides a magnetic core for the one or more conductive coils 18.
The inductive component 10 can be used wherever an inductance is required within an electronic device. For example, an inductive component could be used within an antenna arrangement, resonant circuitry, filtering circuitry or any other suitable component.
Examples of the disclosure provide, for example, for inductive components on wearable electronic devices 38 being flexible, comfortable, water/sweat resistant/proof and/or washable.
The inductive components 10 described herein provide, for example, for mechanical interconnection of different layers 14 of a substrate 12 while also providing electronic functionality.
The use of one or more coils 18 or helical/spiral structure of conductive thread 18 allow for components to be formed having higher inductance than components formed from other methods, for example, printed components.
Furthermore, interlacing/interlocking of a plurality of coils of conductive thread 18 allow complex inductive components 10 to be formed, having, for example, higher inductance.
In examples there is provided a wearable electronic device 38 comprising an inductive component as described herein. See, for example, FIG 8.
FIGS 2A and 2B illustrate an example of an inductive component 10. One or more elements of the inductive component 10 can be as described in relation to FIG 1.
In the example of FIGS 2A and 2B the inductive component 10 is an inductor 54.
FIG 2A illustrates a cross-sectional view of the inductive component 10 and FIG 2B illustrates a top view of the inductive component 10.
The inductive component 10 of FIGS 2A and 2B comprises a substrate 12 and a coil of conductive thread 18 wound through the substrate 12.
As can be seen in the example of FIG 2A, the substrate 12 comprises three layers 14.
In the example of FIG 2A the substrate 12 comprises a magnetic material layer 24 embedded between a first non-magnetic, non-conductive layer 30 and a second non-magnetic, non-conductive layer 32.
That is, in the example of FIG 2A, the first and second non-magnetic, non-conductive layers 30, 32 are the outer layers of the substrate 12.
In the example of FIGS 2A and 2B the magnetic material layer 24 extends beyond the other layers 14 of the substrate 12. However, in some examples the layers 14 can have any suitable shape and/or size.
For example, the first and second non-magnetic, non-conductive layers 30, 32 can completely overlay the magnetic material layer 24. That is, in examples, the non-magnetic, non-conductive layers 30, 32 can encapsulate the magnetic material layer 24.
As illustrated in the example of FIG 2A the coil of conductive thread 18 is wound through the layers 14 of the substrate 12 mechanically interconnecting the layers 14 of the substrate 12.
In the example of FIG 2A, for the sake of clarity, the conductive thread 18 is illustrated as extending beyond the upper and lower surfaces of the substrate 12. However, in examples, the conductive thread 18 can extend by any suitable amount and is some examples can be in contact with upper and lower surfaces of the substrate 12.
In the example of FIG 2A the coil of conductive thread 18 is wound around a portion of the magnetic material layer 24 which provides the magnetic core for the inductor 54.
The inductor comprises connectors 40. The connectors 40 are configured to connect the inductive component 10, 54 to other circuitry components 52.
Any suitable inductor connectors formed using any simple method can be used.
For example, inductor connectors can be obtained by making three-dimensional thread knots or using conductive folding crimps and so on.
The top view illustrated in the example of FIG 2B shows the coil of conductive thread 18.
The portions of the conductive thread 18 on the upper portion are shown in solid lines and the portions of the conductive thread 18 on the lower portion are shown as dotted lines.
Although the coil of conductive thread 18 is illustrated as having a particular form in the example of FIGS 2A and 2B in examples any suitable form can be used.
For example, any suitable size or pattern of turns or loops of coil of conductive thread 18 can be used based on the electronic functionality that the inductive component 10 is to be configured to provide
FIGS 3A and 3B illustrate examples of inductive components 10. One or more elements of the inductive components 10 can be as described in relation to FIG 1.
FIGS 3A and 3B show top views of the inductive components 10.
The inductive component 10 illustrated in the example of FIG 3A is an inductor 54 and is similar to the inductive component 10 illustrated in the examples of FIGS 2A and 2B.
The inductive component 10 of FIG 3A comprises a coil of conductive thread 18 that is wound through a substrate 12 comprising a plurality of layers 14.
The coil of conductive thread 18 comprises connectors 40 to connect the inductive component 10 to other circuitry components 52.
In the example of FIG 3A, the inductive component 10 comprises at least one magnetic strip 26 embedded between layers 14 of the substrate 12.
The magnetic strip 26 is configured to form the magnetic core of the inductor 54.
As illustrated in example FIG 3A, the coil of conductive thread 18 is wound through the layers of the substrate 12 around the magnetic strip 26 to mechanically interconnect the layers 14 of the substrate 12 and embedding the magnetic strip 26 between the layers 14 to locate the magnetic strip 26 in position to act as the magnetic core of the inductor 54.
As can be seen in FIG 3A the coil of conductive thread 18 passes through the substrate 12 outside of the area comprising the magnetic strip(s) 26.
In the example of FIG 3A the outer layers of the substrate 12 are non-magnetic, non-conductive layers, such as any suitable fabrics or textiles.
In the example of FIG 3A the at least one magnetic strip 26 extends beyond the top layer of the substrate 14. However, in examples the at least one magnetic strip 25 can be located entirely within the layers of the substrate 14.
The example illustrated in FIG 3B is similar to the example of FIG 3A. However, in the example of FIG 3B the inductive component 10, which is an inductor 54, comprises at least one magnetic fibre 28 configured to be the magnetic core of the inductor 54.
The turns or loops of the coil of conductive thread in the example of FIG 3B are smaller around the at least one magnetic fibre 28 compared to the turns or loops of the magnetic coil 18 around the magnetic strip 26 illustrated in the example of FIG 3A.
Although the coils of conductive thread 18 are illustrated as having a particular form in the example of FIGS 3A and 3B in examples any suitable form can be used.
For example, any suitable size or pattern of turns or loops of coil of conductive thread 18 can be used based on the electronic functionality that the inductive component 10 is to be configured to provide.
FIGS 4A and 4B illustrate an example of an inductive component 10. One or more elements of the inductive component 10 can be as described in relation to FIG 1.
In the example of FIGS 4A and 4B the inductive component 10 is a transformer 36. In the illustrated example the transformer 36 is a core type transform 36A.
In the illustrated example the inductive component 10 comprises a substrate 12 comprising a plurality of layers 14 and two coils of conductive thread 18a, 18a wound through the substrate 12 mechanically interconnecting the layers 14 of the substrate 12.
FIG 4A illustrates a top view of the magnetic material layer 24 of the inductive component 10. However, any suitable form of magnetic material 16 can be used in the inductive component 10.
In the example of FIG 4A, the magnetic material layer 34 has two limbs/ portions 56, 58 and is configured/shaped as a rectangle or ring shape.
In the example of FIGS 4A and 4B the magnetic material layer 24 is configured/shaped to allow formation of a transformer 36 as the inductive component 10.
The magnetic material layer 24 can comprise any suitable materials. In the example of FIG 4A the magnetic material layer 24 is formed from a non-conductive fabric coated by a magnetic material.
However, any suitable form of magnetic material 16 configured to form a transformer 36 can be used.
FIG 4B illustrates a top view of the inductive component 10 comprising the magnetic material layer 24.
As can be seen from the example of FIG 4B the first coil of conductive thread 18a is wound through the substrate 12 around the first portion or limb 56 of the magnetic material layer 24. The second coil of conductive thread 18b is wound around the second portion or limb 58 of the magnetic material layer 24.
The first and second coils of conductive thread 18 are configured to function as the primary and secondary windings of the transformer 36A.
Although the coils of conductive thread 18 are illustrated as having a particular form in the example of FIGS 4A and 4B in examples any suitable form can be used.
For example, any suitable size or pattern of turns or loops of coil of conductive thread 18 can be used based on the electronic functionality that the inductive component 10 is to be configured to provide
FIGS 5A and 5B illustrate an example of an inductive component 10.
One or more elements of the inductive component 10 can be as described in relation to FIG 1.
The inductive component 10 illustrated in the example of FIGS 5A and 5B is similar to the inductive component 10 illustrated in the example of FIGS 4A and 4B.
However, in the example of FIGS. 5A and 5B the inductive component 10 is configured as a shell type transformer 36b.
FIG 5A illustrates a top view of the magnetic material layer 24 of the inductive component 10. However, any suitable form of magnetic material 16 can be used in the inductive component 10.
In the example of FIG 5A, the magnetic material layer 34 has three limbs/ portions 56, 58, 60 and is configured/shaped to form two adjacent rectangle or ring shapes.
As can be seen in the example of FIG 5B, the transformer 36b comprises a first coil of conductive thread 18a and a second coil of conductive thread 18b wound around the second or central limb/portion 58 of the magnetic material layer 24 to form the primary and secondary windings of the transformer 36B. The coils of conductive thread 18a, 18b also mechanically interconnect the layers 14 of the substrate 12.
Although the coils of conductive thread 18 are illustrated as having a particular form in the example of FIGS 5A and 5B in examples any suitable form can be used.
For example, any suitable size or pattern of turns or loops of coil of conductive thread 18 can be used based on the electronic functionality that the inductive component 10 is to be configured to provide.
FIG 6 illustrates an example of an inductive component 10. One or more elements of the inductive component 10 can be as described in relation to FIG 1.
Inductive component 10 in the example of FIG 6 comprises three coils of conductive thread 18 wound through a substrate 12 comprising a plurality of materials A, B and C.
In the example of FIG 6 the fibres of the materials A, B and C are shown for the purpose of clarity. However, in examples the sizes of the various elements of the inductive component 10 can be changed based on the functionality of the inductive component 10.
In the example of FIG 6 the substrate 12 comprises 3 different fabrics or textiles A, B and C. In the example of FIG 6 materials A, B and C are magnetic fabrics or textiles.
The coils of conductive thread 18 are wound through the substrate 12 to mechanically interconnect the textiles A, B and C. The coils of conductive thread 18 are wound through the substrate 12 to form helical/spiral structures.
In the example of FIG 6 the coils of conductive thread 18 are interlaced/interlocked. In the illustrated example the leftmost coil of conductive thread 18 is interlaced with the central coil of thread 18. In addition, the central coil 18 is interlaced with the rightmost coil of conductive thread 18.
However, in examples, any suitable number of interlaced coils of conductive thread 18 can be used. For example, the coil to the right of FIG 6 can be omitted. Additionally or alternatively additional interlaced coils can be included.
That is, in the example FIG 6, the leftmost coil of conductive thread 18 and the central coil of conductive thread 18 both pass through the left overlapping region 42 of material.
Similarly, in the example of FIG 6 the central coil of conductive thread 18 and the rightmost coil of conductive thread 18 both pass through the right overlapping portion 42 of material.
The example of FIG 6 illustrates a more complex inductive component 10. The interlacing of the plurality of coils of conductive thread 18 magnifies the inductive coupling.
An advantage provided is to combine the magnetic field in a complex volume, enabling larger inductance per volume or inductor density while still providing mechanical interconnection of the materials of the substrate.
Although the coils of conductive thread 18 are illustrated as having a particular form in the example of FIG 6 in examples any suitable form can be used.
For example, any suitable size or pattern of turns or loops of coil of conductive thread 18 can be used based on the electronic functionality that the inductive component 10 is to be configured to provide.
FIGs 7A and 7B illustrate examples of conductive thread 20. FIGS 7A and 7B show examples of conductive thread 20 that can be used in inductive components, such as inductive components as described in relation to at least one of FIGS 1 to 7.
In the example of FIG 7A the conductive thread 20 comprises a core thread 48 coated with different layers.
Any suitable material for the core thread 48 can be used. For example, nylon, polyester, cotton and so on. In examples the core thread 48 material can be one or more conventional sewing threads.
In the example of FIG 7A the core thread 48 is coated with a conductive coating 46. Any suitable material for the conductive coating 46 can be used. For example, any suitable conductive material that enables charge transfer through inductive loops of the coil of conductive thread 18 can be used.
For example, silver, gold, carbon, nickel, copper, and so on can be used.
In FIG 7A the conductive thread 20 comprises an outer insulating layer or coating 22.
Any suitable material can be used for the outer insulating layer or coating 22. For example, polyurethane, polyester, acrylic polymers and so on.
FIG 7B illustrates a further example of a conductive thread 20.
In the example of FIG 7B the conductive thread comprises a conductive core 44 configured as a bulk metal thread. Any suitable material for the conductive core 44 can be used. For example, silver, gold, carbon, nickel, copper and so on.
In the example of FIG 7B the conductive core 44 is coated with an insulating layer 22. The insulating layer can be as described in relation to FIG 7A.
In the examples of FIG 7A and 7B the conductive layers 46 or core 44 enables the charge transfer through the inductive loops of the coil of conductive thread 18, while the insulating layer prevents electrical short circuit between adjacent conductive loops.
In addition, the insulating layer 22 prevents the requirement of an extra coating to insulate the inductive component 10 both on the top and bottom of the substrate 12 which can, for example, be in contact with skin of a wearer of a garment.
The outer insulating layer 22 can also insulate the inductive component 10 from the external environment, protecting the component from environmental factors such as humidity, corrosion, oxidation and similar.
However, in examples, different formations of conductive thread 20 can be used. For example, the insulating layer 22 can be omitted.
FIG 8 shows an example of a wearable electronic device 38 comprising at least one inductive component 10. In the illustrated example the inductive component 10 is an inductive component 10 as described in at least one of FIGS 1 to 7. For example, the wearable electronic device 38 can comprise one or more inductors 53 and/or transformers 36 and so on.
In the example of FIG 8 the wearable electronic device 38 comprises a garment 50 comprising one or more inductive components 10. The garment 50 comprises an item of clothing which is arranged to be worn by a subject. In the example of FIG 8 the garment 50 comprises a shirt.
Other items of clothing could be used in other examples of the disclosure. For instance, the item of clothing could comprise a strap which could be attached to any suitable part of a subject's body, or any other suitable article of clothing such as trousers, sleeve, belt, jacket and similar.
In examples the garment 50 comprises an item of clothing which is arranged to be attached to and/or worn by an animal.
In the example of FIG 8 the inductive component(s) 10 are coupled to other circuitry components 52. The other circuitry components could be antennas, output devices or any other components which can be coupled to an inductive component 10
FIG 9 illustrates an example of a method 900. The method is a method 900 of forming an inductive component 10.
The inductive component 10 can be an inductive component as described in relation to at least one of FIGS 1 to 7.
At block 902 the method comprises forming a substrate 12 comprising a plurality of layers 14, the substrate 12 comprising magnetic material 16.
Any suitable method for forming the substrate 12 comprising a plurality of layers 14 can be used.
For example, any suitable method for overlaying, at least partially, the plurality of layers 14 can be used.
In examples, forming the substrate can comprise any suitable printing or depositing technique and, for example, can include printing or depositing magnetic material in the substrate.
Additionally or alternatively one or more layers 14 of the substrate 12 can be obtained by masking techniques, such as screen printing and so on and/or by conventional printing techniques of the selected region(s).
At block 904 the method 900 comprises forming at least one coil of conductive thread 18 wound through the substrate 12 to mechanically interconnect the plurality of layers 14, wherein at least a portion of the at least one coil of conductive thread 18 is located around at least a portion of the magnetic material 16.
In examples, any suitable method for forming the at least one coil of conductive thread 18 wound through the substrate 12 can be used.
For example, any suitable method for locating the coil of conductive thread 18 through the substrate 12 can be used.
In examples, any suitable sewing, suturing or other similar technique can be used to locate the at least one coil of conductive thread 18 through the substrate 12.
In examples, the at least one coil of conductive thread 18 is wound through the substrate 12 using a curved needle.
In some examples, different methods can be used for locating different coils in the same substrate 12. For example, a first method can be used to locate a first coil of conductive thread 18 in the substrate 12 and a second, different method can be used to locate a second coil of conductive thread 18 in the substrate 12 and so on.
In examples the same or similar method for locating a coil of conductive thread 18 in a substrate 12 can be used for a plurality of coils in the same substrate 12.
In examples, the method 900 comprises forming at least one wearable electronic device 38 comprising the inductive component 10 within the wearable electronic device 38.
Any suitable method for forming the wearable electronic device 38 can be used. For example, one or more portions of the wearable electronic device 38 can be mechanically interconnected by one or more coils of conductive thread 18 that form part of the inductive component.
Additionally or alternatively, in examples, the wearable electronic device 38 can comprise one or more inductive components 10, as described in at least one of FIGS 1 to 7, located within the wearable electronic device 38.
Examples of the disclosure therefore provide inductive components 10 that are suitable for use in wearable electronic devices. However, it is to be appreciated that the inductive components 10 could also be used in other types of devices, for instance, the inductive components 10 could be used in any devices where it can be useful to have a small inductive component 10.
The use of inductive components 10 as described herein can provide components suitable for wearable devices and providing higher inductances. This can allow different functionality, for example measurement of changes in posture and so on using change in inductance.
Where a structural feature has been described, it may be replaced by means for performing one or more of the functions of the structural feature whether that function or those functions are explicitly or implicitly described.
The term 'comprise' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising Y indicates that X may comprise only one Y or may comprise more than one Y. If it is intended to use 'comprise' with an exclusive meaning then it will be made clear in the context by referring to "comprising only one.." or by using "consisting".
In this description, reference has been made to various examples. The description of features or functions in relation to an example indicates that those features or functions are present in that example. The use of the term 'example' or 'for example' or 'can' or 'may' in the text denotes, whether explicitly stated or not, that such features or functions are present in at least the described example, whether described as an example or not, and that they can be, but are not necessarily, present in some of or all other examples. Thus 'example', 'for example', 'can' or 'may' refers to a particular instance in a class of examples. A property of the instance can be a property of only that instance or a property of the class or a property of a sub-class of the class that includes some but not all of the instances in the class. It is therefore implicitly disclosed that a feature described with reference to one example but not with reference to another example, can where possible be used in that other example as part of a working combination but does not necessarily have to be used in that other example.
Although embodiments have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the claims.
Features described in the preceding description may be used in combinations other than the combinations explicitly described above.
Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.
Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.
The term 'a' or 'the' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising a/the Y indicates that X may comprise only one Y or may comprise more than one Y unless the context clearly indicates the contrary. If it is intended to use 'a' or 'the' with an exclusive meaning then it will be made clear in the context. In some circumstances the use of 'at least one' or 'one or more' may be used to emphasis an inclusive meaning but the absence of these terms should not be taken to infer and exclusive meaning.
The presence of a feature (or combination of features) in a claim is a reference to that feature or (combination of features) itself and also to features that achieve substantially the same technical effect (equivalent features). The equivalent features include, for example, features that are variants and achieve substantially the same result in substantially the same way. The equivalent features include, for example, features that perform substantially the same function, in substantially the same way to achieve substantially the same result.
In this description, reference has been made to various examples using adjectives or adjectival phrases to describe characteristics of the examples. Such a description of a characteristic in relation to an example indicates that the characteristic is present in some examples exactly as described and is present in other examples substantially as described.
The use of the term 'example' or 'for example' or 'can' or 'may' in the text denotes, whether explicitly stated or not, that such features or functions are present in at least the described example, whether described as an example or not, and that they can be, but are not necessarily, present in some of or all other examples. Thus 'example', 'for example', 'can' or 'may' refers to a particular instance in a class of examples. A property of the instance can be a property of only that instance or a property of the class or a property of a sub-class of the class that includes some but not all of the instances in the class. It is therefore implicitly disclosed that a feature described with reference to one example but not with reference to another example, can where possible be used in that other example as part of a working combination but does not necessarily have to be used in that other example.
Whilst endeavoring in the foregoing specification to draw attention to those features believed to be of importance it should be understood that the Applicant may seek protection via the claims in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not emphasis has been placed thereon.

Claims

An inductive component comprising:
a substrate comprising a plurality of layers;

magnetic material; and

at least one coil of conductive thread wound through the substrate to mechanically interconnect the plurality of layers, wherein at least a portion of the at least one coil of conductive thread is located around at least a portion of the magnetic material.
An inductive component as claimed in any preceding claim, wherein the conductive thread comprises an outer insulating layer.
An inductive component as claimed in any preceding claim, wherein the substrate comprises at least one magnetic material layer and wherein the magnetic material comprises at least a portion of the at least one magnetic material layer.
An inductive component as claimed in any preceding claim, wherein at least a portion of the magnetic material comprises at least one magnetic strip and/or at least one magnetic fibre.
An inductive component as claimed in any preceding claim, wherein the substrate comprises a first non-magnetic, non-conductive layer and a second non-magnetic, non-conductive layer, and wherein the first non-magnetic, non-conductive layer and the second non-magnetic, non-conductive layer are the outer layers of the substrate.
An inductive component as claimed in any preceding claim wherein at least one of the layers is formed from fabric or textile.
An inductive component as claimed in any preceding claim, comprising a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first coil and the second coil are configured to form a transformer.
An inductive component as claimed in claim 7, wherein the transformer comprises at least one of a shell type transformer and a core type transformer.
An inductive component as claimed in any preceding claim, comprising a first coil of conductive thread wound through the substrate and a second coil of conductive thread wound through the substrate, wherein the first and second coils are interlaced.
A wearable electronic device comprising an inductive component as claimed in at least one of claims 1 to 9.
A method of forming an inductive component comprising:
forming a substrate comprising a plurality of layers, the substrate comprising magnetic material; and

forming at least one coil of conductive thread wound through the substrate to mechanically interconnect the plurality of layers, wherein at least a portion of the at least one coil of conductive thread is located around at least a portion of the magnetic material.
A method as claimed in claim 11, wherein the at least one coil of conductive thread is wound through the substrate using a curved needle.
A method as claimed in any of claims 11 to 12, wherein the substrate comprises at least one magnetic material layer and wherein the magnetic material comprises at least a portion of the at least one magnetic material layer.
A method as claimed in any of claims 11 to 13, wherein at least one of the layers is formed from fabric or textile.
A method as claimed in any of claims 11 to 14, comprising forming at least one wearable electronic device comprising the inductive component within the wearable electronic device.