GB2605443A

GB2605443A - Fabric article and method of making the same

Info

Publication number: GB2605443A
Application number: GB2104728.7A
Authority: GB
Inventors: Riaz Naeem
Original assignee: Prevayl Innovations Ltd
Current assignee: Prevayl Innovations Ltd
Priority date: 2021-04-01
Filing date: 2021-04-01
Publication date: 2022-10-05
Also published as: GB202104728D0

Abstract

Method of weft knitting fabric 100 with two bed machine by knitting courses of yarn with a first sequence of tuck-rib/cardigan stitches while racking one of the needle beds relative to the other needle bed to form first section 113 of a base component 101 with wales extending in first direction, knitting conductive yarn to form a first conductive region 107 connected to the first section 113 of the base component 101, knitting second courses of yarn to form a second section 115 of a base component 101 connected to the first conductive region 107 and the first section 113 of the base component 101 using tuck-rib/cardigan stitches while racking one of the needle beds relative to the other needle bed, the wales of the second section 115 of the base component 101 extending in a second direction different to the first direction such that a peak or valley is formed along an edge 103a, 103b of the base component 101 in the wale direction, the first conductive region 107 located proximate the edge of the base component 101 in which the peak or valley is formed. Also claimed is a fabric and assembly.

Description

FABRIC ARTICLE AND METHOD OF MAKING THE SAME

The present invention is directed towards a fabric article and method of making the same. The present invention is directed, in particular, towards a fabric article comprising a fabric base component and conductive regions provided on the base component.

Background

Fabric articles comprising conductive regions such as in the form sensing components can be designed to interface with a wearer of the article to determine information such as the wearer's heart rate and rate of respiration. The sensing components may comprise electrodes and connection terminals electrically connected together via an electrically conductive pathway. An electronics module for processing and communication can be removably coupled to the connection terminals so as to receive the measurement signals from the electrodes. The fabric articles may be incorporated into or form a wearable article such as a garment.

It is desirable to form conductive regions from conductive yarn that is knitted with a base fabric layer (base component) during a single knitting operation. This process simplifies the process of integrating electrodes into wearable articles and avoids the need for metallic or conductive polymer elements to be incorporated into a fabric. Conductive fabric electrodes are also comfortable to wear and can look, behave and feel like normal garment fabric.

Knitting conductive yam is preferred over other techniques, such as weaving, as knitted structures are able to stretch without directly stretching the yarns used to form the knitted structure. Instead, when a knitted structure is stretched, the loops are deformed. This contrasts with woven articles where the yarns are directly stretched when the woven article is stretched.

It will be appreciated that stretching a conductive yarn can change its electrical properties.

United States Patent Application Publication No. 2012/0144561 Al discloses knitting techniques for forming three-dimensional textile electrodes. A conductive surface forming the electrode is knit using a back needle bed of a knitting machine while an isolating surface is knit using the front needle bed. A thread network is provided in a space formed between the conductive surface and the isolating surface using a tucking technique.

It is desirable to overcome at least some of the problems associated with the prior art, whether explicitly discussed herein or otherwise.

Summary

According to the present disclosure there is provided a fabric article and method of making the same as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the disclosure, there is provided a method of weft knitting a fabric article using a knitting machine comprising first and second needle beds.

The method comprises knitting a first plurality of courses of yarn using a first sequence of tuck-rib stitches while selectively racking one of the first and second needle beds relative to the other of the first and second needle beds to form a first section of a base component with wales extending in a first direction.

The method comprises knitting conductive yarn to form a first conductive region that is connected to the first section of the base component.

The method comprises knitting a second plurality of courses of yarn to form a second section of the base component that is connected to the first conductive region and the first section of the base component, the knitting comprises using a second sequence of tuck-rib stitches while selectively racking one of the first and second needle beds relative to the other of the first and second needle beds.

The second section of the base component has wales extending in a second direction different from the first direction such that a peak or valley is formed along an edge of the base component in the wale direction.

The first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.

The term "first bed" may refer to the front bed or the back bed of a flat-bed knitting machine such as a V-bed knitting machine. The "second bed" may refer to the other of the front bed and the back bed of the flat-bed knitting machine.

The yarn used to the knit the base component may comprise non-conductive yarn. The base component may be a non-conductive base component and may comprise only non-conductive yarn. Although conductive yarn may be incorporated into the base component if desired.

The knitting machine may be a flat bed knitting machine such as a V-bed flat knitting machine.

The second sequence may be the reverse of the first sequence such that stitches performed on the first bed for the first sequence are performed on the second bed for the second sequence, and stitches performed on the second bed for the first sequence are performed on the first bed for the second sequence.

Knitting the first plurality of courses may comprise knitting a plurality of pairs of courses, wherein knitting each pair comprises: knitting a first course while the first and second beds are in a first position; knitting a second course while one of the first and second beds is racked relative to the other of the first and second beds so as to move the one of the first and second beds away from the first position.

The second course may comprise the reverse of the stitches used for the first course such that stitches performed on the first bed for the first course are performed on the second bed for the second course, and stitches performed on the second bed for the first course are performed on the first bed for the second course.

Knitting the second plurality of courses may comprise knitting a plurality of pairs of courses, wherein knitting each pair comprises: knitting a first course while the first and second beds are in a first position; knitting a second course while one of the first and second beds is racked relative to the other of the first and second beds so as to move the one of the first and second beds away from the first position.

Knitting the conductive yarn to form the conductive region may comprise knitting a plurality of courses of conductive yarn using one of the first and second beds to form a raised conductive region that extends away from a surface of the base component.

The method may further comprise knitting at least one course of filler yarn using tuck stitches such that the filler yarn is deposited within a space formed between the first conductive region and the base component.

Knitting the conductive yarn may further comprise forming a second conductive region that is connected to the first and second sections of the base component.

The first and second conductive regions may be spaced apart from one another.

The second conductive region may form an electrode for monitoring activity at a body surface.

The conductive regions may be a unitary knitted structured form from a single length of conductive yarn. This may mean that the first conductive region, second conductive region and optional third conductive region are formed from the same conductive yam during a single knitting operation. This simplifies the manufacturing process and increases the comfort of the fabric article as elements such as wires and hardware connectors are not required.

The first conductive region may be knitted using the first bed and the second conductive region may be knitted using the second bed such that the first and second conductive regions are provided on opposing surfaces of the base component.

Knitting the conductive yarn may further comprise forming a third conductive region that is connected to the first and second sections of the base component, wherein the third conductive region electrically connects the first conductive region to the second conductive region.

The base component and the conductive region may form a continuous body of well knitted fabric.

The first conductive region may form a connection terminal for electrically connecting with an electronics module.

The base component and the conductive region may form a continuous body of well knitted fabric. A continuous body of knitted fabric that comprises a conductive region integrally formed with the base component. This simplifies the manufacturing process as the conductive regions and base component are manufactured during a single knitting operation. The fabric article structure simplifies the knitting techniques required to form the conductive region integrally with the base component. That is, the fabric article structure facilitates the manufacture of the continuous body of fabric in a single knitting operation.

A well knitted fabric article manufactured according to the method of the first aspect of the disclosure is also provided.

According to a second aspect of the disclosure, there is provided a computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine comprising a first bed and a second bed, are operable to cause the computer to control the knitting machine to perform the method of the first aspect of the disclosure.

According to a third aspect of the disclosure, there is provided a weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive regions formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component, wherein the first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.

According to a fourth aspect of the disclosure, there is provided an assembly.

The assembly comprises a first weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive region formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component.

The assembly comprises a second weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive region formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component, The first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.

The assembly may further comprise a fabric layer, wherein the first and second fabric articles are attached to the fabric layer such that the first conductive regions are located proximate to one another.

The assembly may form a wearable article such as a garment.

According to a fifth aspect of the disclosure, there is provided a fabric article comprising a base component having a tapered end region and a first conductive region connected to the base component and located proximate to the tapered end region.

The fabric article may further comprise a second conductive region connected to the base component.

The second end region may be located proximate to a second end region opposing the tapered end region.

The second end region may be a tapered end region.

The first and second conductive regions may be provided on opposing surfaces of the base component.

The fabric article may further comprise a third conductive region connected to the base component.

The third conductive region may electrically connect the first conductive region to the second conductive region.

The fabric article may be a knitted fabric article.

The fabric article may be a weft knitted fabric article.

The base component may have a racked-rib structure.

According to a sixth aspect of the disclosure, there is provided an assembly.

The assembly comprises a fabric layer.

The assembly comprises a first fabric article comprising: a base component having a tapered end region; and a conductive region connected to the base component and located proximate to the tapered end region.

The assembly comprises a second fabric article comprising: a base component having a tapered end region; and a conductive region connected to the base component and located proximate to the tapered end region.

The first and second fabric articles are attached to the fabric layer such that the tapered end regions are located adjacent to one another.

Brief Description of the Drawings

Examples of the present disclosure will now be described with reference to the accompanying drawings, in which: Figure 1 is a simplified schematic side-on view of a V-bed knitting machine; Figures 2 to 4 are simplified schematic top-down views of the front and back beds of the knitting machine in Figure 1; Figures 5 to 6 are knitting notation diagrams showing a method of knitting loops using the front bed or the back bed of a knitting machine; Figures 7 and 8 show the front and back surfaces of a fabric article knitting according to the methods of Figures 5 and 6; Figure 9 is a knitting notation diagram showing a method of knitting loops using both the front bed and the back bed of a knitting machine; Figures 10 and 11 are knitting notation diagrams showing a method of knitting tuck-stitches using the front bed or the back bed of a knitting machine; Figure 12 is a knitting notation diagram showing a method of knitting a combination of knitting loops and float stitches and a combination of tuck-stitches and float-stitches using the front and/or back bed of a knitting machine; Figure 13 is a knitting notation diagram showing a method of knitting full-cardigan stitches using a knitting machine; Figure 14 shows a fabric article made according to the method of Figure 13; Figure 15A is a knitting notation diagram showing a method of knitting full-cardigan stitches with racking to form a racked-rib structure; Figure 15B shows the racking of the needle beds during the method of Figure 15A; Figure 16 shows a fabric article with a racked-rib structure made according to the method of Figure 15A; Figures 17A-17C show a fabric article; Figures 18 and 19 shows an assembly comprising two of the fabric articles of Figures 35 17A-17C; Figures 20A-20C show an example fabric article according to aspects of the present disclosure; Figures 21A-21B show another example fabric article according to aspects of the present disclosure;

B

Figures 22 shows an assembly comprising two of the fabric articles of Figures 20A-20C; Figures 23 shows assembly comprising two of the fabric articles of Figures 21A-21B; Figure 24 shows another example assembly comprising two of the fabric articles of Figures 20A-20C; Figure 25 shows another example assembly comprising two of the fabric articles of Figures 21A-21B; Figures 26A-26D are knitting notation diagrams showing an example method of knitting a fabric article according to aspects of the present disclosure; Figure 27 shows another example fabric article according to aspects of the present

disclosure; and

Figure 28 shows another example fabric article according to aspects of the present disclosure.

Detailed Description

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the disclosure is provided for illustration purpose only and not for the purpose of limiting the disclosure as defined by the appended claims and their equivalents.

It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

The present disclosure relates to fabric articles. The terms fabric and textile are used interchangeably and are not intended to convey different meanings. The fabric articles are knitted from yarns.

The fabric articles may form or be incorporated into a wearable article. "Wearable article" as referred to throughout the present disclosure may refer to any form of article which may be worn by a user such as a smart watch, necklace, bracelet, or glasses. The wearable article may be a garment. The garment may refer to an item of clothing or apparel. The garment may be a top.

The top may be a shirt, t-shirt, blouse, sweater, jacket/coat, or vest. The garment may be a dress, brassiere, shorts, pants, arm or leg sleeve, vest, jacket/coat, glove, armband, underwear, headband, hat/cap, collar, wristband, stocking, sock, or shoe, athletic clothing, personal protective equipment, swimwear, wetsuit or drysuit The garment may be a tight-fitting garment. Beneficially, a tight-fitting garment helps ensure that the sensor devices of the garment are held in contact with or in the proximity of a skin surface of the wearer. The garment may be a compression garment. The garment may be an athletic garment such as an elastomeric athletic garment.

The fabric articles may be constructed from natural fibres, synthetic fibres, or a natural fibre blended with one or more other materials which can be natural or synthetic. The yarn may be cotton. The cotton may be blended with polyester and/or viscose and/or polyamide according to the particular application. Silk may also be used as the natural fibre. Cellulose, wool, hemp and jute are also natural fibres that may be used in the wearable article. Polyester, polycotton, nylon and viscose are synthetic fibres that may be used in the wearable article.

The fabric articles according to the present disclosure comprise knitted fabric. This contrasts with other fabric constructions such as woven fabrics. Woven and knitted fabrics differ in the way yarns are interwoven or knotted together. A woven fabric is created by interweaving pre-tensioned lengths of yarn horizontally in between threads running vertically. These vertical, or warp threads, wrap themselves around the horizontal, or weft thread, after every course, and are themselves pre-tensioned.

During the manufacture of a woven fabric, all of the yarns running in every direction must be pulled fight at all teams. If the yarns are not fight during knitting, the needles will snag on slacker yarns and break, causing mechanical damage.

Moreover, woven fabrics incorporating conductive yarn are potentially subjected to a change of resistance when stretched apart because, when stretching a woven fabric, the yarns and thus the conductive particles in the yarn will be stretched further apart. This property is undesirable for sensing operations such as for fabric-based sensing electrodes.

The present disclosure is directed towards knitted fabrics and, in particular, weft knitted fabrics. Weft knitted fabrics can be knit from a single yarn, but in aspects of the present disclosure multiple yarns are used so as to provide different regions of the fabric with different properties. In well knitted fabrics, a well thread is pulled through already formed loops of the same thread and, unlike warp knitting, is not required to be held taut or under stress from a warp thread. This construction allows for stitches (loops) in the fabric article to deform and alter their shape under stress without stretching the yarn itself This helps maintain a constant level of electrical resistance.

Warp knitted fabrics are another form of knitted article and can be considered a hybrid between woven and knitted. They are formed using loops, but each column of loops is made from its own thread. Warp knitted threads may allow for more stretch than a woven fabric but are generally not as stretchy as weft knitted fabrics.

To aid in the understanding of the invention, a brief overview of knitting machines and the stitches that knitting machines can generate is provided below. This explanation is not intended to be a full disclosure of the common general knowledge of the skilled person, but instead is only provided to aid in the understanding of the invention.

Figures 1 to 4 show simplified schematic diagrams of a conventional V-bed flat knitting machine 1 which is suitable for use in knitting the fabric articles described herein.

The knitting machine 1 comprises a front needle bed 3 and a back needle bed 5. The front and back needle beds 3, 5 diagonally approach once another at an angle generally between 90 degrees and 104 degrees to each other, giving an inverted V-shape appearance.

The front and back needle beds 3, 5 each comprise a large number of needles 7, 9. The needles are typically latch needles. Each needle 7,9 is able to create and manipulate individual stitches. The number of needles per inch is referred to as the gauge of the knitting machine 1. Typically, knitting machines have a gauge of between 7 and 20.

The needles 7, 9 are controlled by a needle cam 11 that traverses across the needle beds 3, 5 in both left-to-right and right-to-left directions. The needle cam 11 is designed to knit a course of loops on both the front bed and the back bed during a traverse in either the left or the right direction.

Yarn is fed to the needle beds 3, 5 by one or more yarn carriers (not shown). Multiple yarn carriers are typically used to allow for a variety of yarns to be introduced into the fabric article at desired locations.

The needle beds 3, 5 are able to move relative to one another by a process called racking. Racking moves one of the needle beds by one or more needle tricks past the other needle bed, either towards the right or the left. A needle trick is a slot on the needle bed in which a needle moves back and forth. The front and back needle beds 3, 5 are aligned in Figure 2. In Figure 3, the back needle bed 5 has been racked to the left relative to the front needle bed 3. In Figure 4, the back needle bed 5 has been racked to the right relative to the front needle bed 3.

For most knitting machines, only the back needle bed 5 is able to be racked while the front needle bed 3 stays in a fixed position. However, this is not true for all machines, and front needle beds 3 may also be racked if desired Figure 5 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the front needle bed 3 of the knitting machine 1.

The diagram comprises several rows of dots where each dot represents a needle on either the front bed 3 or the back bed 5.

The rows are grouped into pairs. In each pair, one row represents needles on the front needle bed 3 and the other row represents needles on the back bed 5. Each pair of dots show the knitting operations performed to form a knitted course of the fabric article.

The type of knitting operation performed is represented by the lines that traverse along the dots. Here, the knitting operations are knitted loops as indicated by the lines looping around the dots representing needles on the front bed 3.

The diagram is read from bottom to top. This means that the knitting operations Si are performed first followed by 82, 83, 84, 85 and 86 in order. Each of the knitting operations 8186 involve forming knitted loops using the front needle bed 3 only. The back needle bed 5 is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

Figure 6 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the back bed 5 of the knitting machine 1. Each of the knitting operations 811-816 involve forming knitted loops using back needle bed 5 only. The front needle bed 3 is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

Figures 7 and 8 show a knitted fabric article 20 that may be formed as a result of front-bed only knitting using the techniques shown in Figure 5 or back-bed only knitting using the techniques shown in Figure 6. The knitted fabric article 20 is a single-faced structure as only one of the needle beds 3, 5 is used to form the knitted loops. Figure 7 shows the face 21 of the fabric article 20 and Figure 8 shows the back 23 of the fabric article 2.

Figure 9 shows an example knitting notation diagram in which a plurality of courses of knitting loops are formed using both the front and back needle beds 3,5. Each of the knitting operations S21-S27 involve forming knitted loops using both the front and the back needle bed 3, 5. This can be referred as double-knitting. The resultantly formed knitted article comprises a number of courses of knitted loops and has a double-faced structure as compared to the single-faced structure of the fabric article formed using the operations shown in Figures 5 and 6.

Figures 10 and 11 show example knitting notation diagram in which a plurality of courses (831836 and 841-847) of tuck stitches are formed using the front needle bed 3 only (Figure 10) or using the back needle bed 5 only (Figure 11). Tuck stitches are produced when a needle holding an existing loop also receives a new loop which rather than being intermeshed through the existing loop is tucked in behind the existing loop on the reverse side of the stitch. Tuck stitches are represented in the diagram by as a "V" (or inverted "V") shape that goes around the needle that performs the tuck stitch.

Figure 12 is an example knitting notation diagram in which float stitches are interspersed between other needle stitches. Float stitches are produced when a needle misses the yarn which instead floats over to the next chosen needle. Floats are represented in the needle diagram as a bypassed point.

Knitting operation S51 involves a series of knitted loops on the front needle bed (3) with float stitches in between. In other words, every other needle on the front needle bed (3) is used to knit a loop.

Knitting operation S52 involves a series of knitted loops on the back needle bed (5) with float stitches in between, Knitting operation S53 involves a series of tuck stitches on the back needle bed (5) with float stitches in between.

Knitting operation 854 involves a series of tuck stitches on the front needle bed (3) with float stitches in between.

Knitting operation S55 involves a series of tuck stitches alternatingly performed on the front needle bed (3) and the back needle bed (5) with float stitches in between.

Tuck-rib stitches are another form of knit structure formed by using knitted loops on one needle bed and tuck-stitches on the other needle bed. Tuck-rib stitches can be used in full-cardigan stitches.

Figure 13 is an example knitting notation diagram which shows a series of full-cardigan stitches. Full-cardigan stitches use repeating pairs of knit courses where the second course in each pair uses the reverse of the stitches used for the first course in each pair. The first and second courses both use tuck stitches on one needle bed and knitted loops on the other needle bed.

The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border. Tuck loops can increase the fabric thickness and make it heavier in weight and bulkier in handle.

The knitting operation 361 is a sequence of knitted loops on the front bed and tuck stitches on the back bed. The knitting operation S62 is the reverse of the sequence of 561 and has tuck stitches on the front bed and knitted loops on the back bed. Operations 363-366 are a repetition of the sequences 561 and 562.

Figure 14 shows a knitted fabric article 30 formed as a result of the knitting operations of Figure 13. The full-cardigan stitches result in a balanced 1 x 1 tuck-rib structure with the same appearance when viewed from both faces of the fabric. This drawing is obtained from the textbook: Knitting technology (2001) David J Spencer, Third edition, Woodhead Publishing Limited, Cambridge, UK (Figure 18.6, page 219).

Tuck-rib stitches, particularly as used in the two-course repeat manner of full-cardigan sequences, are suitable for racking to produce racked-rib structures. Racking involves moving one of the needle beds 3, 5 in the left or right direction relative to the other of the needle beds as shown in Figures 2 to 4. A racked-rib structure means a knitted structure formed using (tuck- 30)rib stitches while selectively racking one needle by one or more needle ticks past the other needle bed either towards the left or the right.

Figure 15A is an example knitting notation diagram which shows a series of full-cardigan stitches performed with racking of the needle bed. Figure 15B shows the position of the needle beds relative to one another during the knitting of the knitted courses.

The first knitted course knitted in operation 371, involves a sequence of knitted loops on the first bed and tuck stitches on the back bed. The front needle bed 3 is aligned with the back needle bed.

For the second knitted course knitted in operation S72, the reverse of the sequence knitted in sequence 371 is knitted. For this course, the back needle bed 5 is racked to the left relative to the front needle bed 3 by one needle. The racking in the knitting notation diagram is indicated by the arrow in the left-hand column.

For the third knitted course S73, the same sequence as S71 is performed. The back needle bed 5 is moved back into alignment with the front needle bed 3. This means that the front and back needle beds 3, 5 are aligned during the knitting of this course.

For the fourth knitted course S74, the same sequence as S72 is performed. The back needle bed 5 is racked to the left relative to the front needle bed 3 by one needle.

For the fifth knitted course S75, the same sequence as 371 is performed. The back needle bed 5 is moved back into alignment with the front needle bed 3. This means that the front and back needle beds 3, 5 are aligned during the knitting of this course.

For the sixth knitted course S76, the same sequence as S72 is performed. The back needle bed 5 is racked to the left relative to the front needle bed 3 by one needle.

In other words, Figure 15A shows a full-cardigan sequence with racking. Every course has tuck-stitches on one bed and knitted loops on the other bed. For odd-numbered courses, the front and back needle beds 3, 5 are aligned, and for even-numbered courses the back needle bed 5 is racked to the left of the front needle-bed 3.

Figure 16 shows a knitted fabric article 40 formed as a result of the knitting operations of Figures 15A and 15B.

Full-cardigan sequences with racking are used to form a decorative zig-zag edge in the wale direction (perpendicular to the course direction). This decorative edge may be referred to as a Vandyke, zigzag stitch, or zigzag selvedge edge.

In an example operation, full-cardigan stitches are knitted while every odd course is racked to the right and every even course is racked to the left. After a desired number of courses, a full round of cardigan stitches are knitted without racking. This routine may be repeated as desired to form the desired number of zig-zags in the wale direction of the fabric article.

Referring to Figures 17A-17C there is shown an example fabric article 40.

The fabric article 40 comprises a base component 41 having a first surface 42 and a second surface 43 that opposes the first surface 42. The base component 41 has a pair of straight-edged end regions 44, 45. The base component 41 has an approximate rectangular shape.

A plurality of conductive regions 46, 47, 48 are provided on the base component 41.

The first conductive region 46 is attached to the second surface 43 of the base component 41 and is provided proximate to the end region 44.

The first conductive region 46 is positioned proximate to the end region 44 but is not provided in the end region 44 and does not directly abut against the outer edge of the end region 44. Instead, the end region 44 provides an overhang region of the base component 41 which extends from the first conductive region 46 to the outer edge of the base component 41.

The end region 44 improves the attachment of the fabric article 40 to a fabric layer 51 (explained in relation to Figure 18) and helps prevent the fabric article 40 from lifting off the fabric layer 51 after repeated user/washes. Moreover, the overhand region 44 helps ensure that there is consistent spacing between first conductive regions 46 for adjacent fabric articles 40 as also explained in relation to Figure 18.

The second conductive region 47 is attached to the first surface 42 of the base component 41 and extends across part of the base component 41 to the end region 45. The conductive region 47 forms an electrode.

The third conductive region 48 is attached to the second surface 43 of the base component 41.

The conductive region 48 extends along the second surface 43 in the length direction of the base component 41 and electrically connects the first conductive region 46 to the second conductive region 47 Referring to Figure 18, there is shown an assembly 50 comprising a fabric layer 51 and two of the fabric articles 40 shown in Figures 17A-17C. The assembly 50 forms a wearable article such as a garment. The first surfaces 42 of the fabric articles 40 are attached to the fabric layer 51.

The two fabric articles 40 are arranged such that the end regions 44 are located adjacent to one another. The end regions 44 may abut one another or there may be a small gap between the end regions. This arrangement means that the first conductive regions 46 are located proximate to one another.

The overhang regions 44 provide extra material between the first conductive regions 46 which provides additional surface area for bonding (or otherwise attaching) the base component 41 to the fabric layer 51. This helps prevent the base component 41 and thus the conductive regions 46 from lifting up from the fabric layer 51 after repeated use.

The overhang regions 44 help ensure consistent spacing between the conductive regions 46. This is beneficial as the conductive regions 46 are generally required to be spaced apart from one another by a fixed distance that matches the spacing between contact pads 311 of an electronics module (explained in relation to Figure 19).

Referring to Figure 19, there is shown a removeable electronics module 300 positioned on the assembly/article 500.

The electronics module 300 comprises a housing 301. A pair of electrical contacts 311 are provided on the lower surface 303 of the housing 301. The contacts 311 are electrically coupled to a controller 309 disposed within the housing 301.

When positioned on the wearable article 500, the contacts 311 are brought into physical contact with the connection regions 46 of the fabric articles 40. In this way, a temporary electrical connection is formed between the controller 309 of the electronics module 300 and the electrodes 47 of the fabric article 100. The electrodes 47 are able to contact a skin surface when the wearable article is worn so as to measure signals from the skin surface and/or apply signals to the skin surface. Providing the electrodes 47 and the connection regions 46 on opposing surfaces enables the electronics module 300 to be connected to the electrode 47 from an outer surface which faces away from the skin surface when worn without additional modification to the fabric articles 40.

The wearable article 50 may further comprise a holder for temporarily retaining the electronics module 300 and holding the electronics module 300 in contact with the connection regions 46.

The holder may, for example, be a pocket integrally knit with the base component 41 of the fabric article 4001 a separate layer of the wearable article (e.g. fabric layer 51). The pocket may have an opening which enables access inside the pocket. The electronics module 300 may be inserted into and removed from the pocket. When positioned in the pocket, the contacts 311 are brought into conductive connection with the connection regions 46.

The electronics module 300 is further arranged to wirelessly communicate data to a mobile device when coupled to the wearable article. Various protocols enable wireless communication between the electronics module 300 and the mobile device Example communication protocols include Bluetooth 0, Bluetooth Low Energy, and near-field communication (NFC).

The fabric layer 51 is positioned proximate to skin surface S of wearer such that the electrodes 47 are able to brought into contact with the skin surface S. The fabric layer 51 may comprise openings to expose the electrodes 47.

While the overhang regions 44 are beneficial in ensuring a secure attachment of the fabric articles 40 to the fabric layer 51, they can increase the cost of the fabric article and the manufacturing time as more material is required to form the base component than if the overhang region were not provided. For example, if the base component is knitted, extra yarn is needed and further knitted stitches are required which increase both the cost and knitting time required to form the fabric article.

Moreover, the end regions 44 can result in an electrical short being formed between the contact pads 311 which can reduce the quality of the received measurement signals. For example, the pair of electrodes 47 may be used to perform a differential voltage measurement such as to determine an electrocardiograph, ECG, signal for the user. An accurate differential measure requires that the contact pads 311 are electrically isolated from one another.

Figure 19 shows how an electrical short may be formed. Moisture 'M' from the skin surface S (such as due to sweat) may permeate into the base components 101 via the fabric layer 51 and form a moisture bridge between the contact pads 311.

It is an object of the present disclosure to provide a fabric article construction and manufacturing process that avoids some or all of the problems outlined above.

Figures 20A-20C show a fabric article 100 according to aspects of the present disclosure.

The fabric article 100 is an elongate and narrow strip of material. The fabric article 100 is able to be worn so as to obtain measurement signals from the wearer. The fabric article 100 may be used to form a chest strap or wrist strap or may be integrated into a separate wearable article such as a garment. The fabric article 100 may be adhesively bonded to an inner surface of a garment for example such as by using an adhesive film.

The fabric article 100 comprises a continuous body of fabric 100. Here, continuous body of fabric 100, refers to a unitary fabric structure that is integrally knit. This means that seams are not provided between different sections of the fabric article 100. In other words, the fabric article is seamless. Although the fabric is seamless, different types of yarns such as conductive and nonconductive yarns are provided in the continuous body of fabric 100.

The fabric article 100 comprises a base component 101 having the racked-rib structure.

The fabric article 100 has a generally rectangular shape with two end regions 103, 105. The end region 103 terminates in outer edges 103a, 103b and the end region 105 terminates in outer edges 105a, 105b.

The base component 101 is knit by knitting courses of yarn. The courses extend in the X-direction. The courses extend along the length of the base component 101 from the outer edges 105a, 105b to the outer edges 103a, 103b.

The base component 101 has a first section 113 that comprises a plurality of courses of yarn (extending in the X-direction). The first section 113 extends from the outer edge 119 of the fabric article 100 to the centre of the fabric article 100.

In the first section 113, the wales extend in a first direction. This results in the formation of the edges 103a, 105a along the wale direction (Y-axis) that are angled relative to the course direction (X-axis). The wale edges 103a, 105a of the first section 113 of the base component 101 therefore do not extend perpendicularly to the course direction. The extension of the wales in a non-perpendicular structure is achieved as a result of the racked-rib structure of the base component 101.

The base component 101 has a second section 115 that comprises a plurality of courses of yarn (extending in the X-direction). The second section 115 extends from the centre 'C' of the fabric article 100 to the outer edge 121 of the fabric article 100.

In the second section 115, the wales extend a second direction different to the first direction. This results in the formation of edges 103b, 105b along the wale direction (Y-axis) that are angled relative to the course direction (X-axis). The wale edges 103b, 105b of the second section 115 of the base component 101 therefore do not extend perpendicularly to the course direction.

The first section 113 and second section 115 cooperate to form a peak along the edges 103a, 103b of the base component 101 and a valley along the edges 105a, 105b of the base component 101. This means that the base component 101 has tapered end regions 103, 105 as compared to the straight end regions 44 of the fabric article 40 shown in Figures 17A-17C.

The tapered end regions 103, 105 reduce the amount of fabric material required to provide the fabric overhang regions which are beneficial in ensuring secure attachment of the fabric article 100 to a separate fabric layer. Using less material reduces the cost of the base component 101 and reduces the manufacturing time.

Moreover, reducing the amount of fabric in the overhang region helps reduce the opportunities for a moisture bridge to be formed between the conductive regions of adjacent fabric articles as explained in greater detail below.

The base component 101 has a first surface 102 and a second surface 104 opposing the first surface 102. The first surface 102 and the second surface 104 are parallel to one another and spaced apart along the Z axis. In use, the first surface 102 faces towards the skin surface of the wearer of the fabric article 100 and the second surface 104 faces away from the skin surface of the wearer.

The fabric article 100 further comprises three conductive regions 107, 109, 111. The three conductive regions 107, 109, 111 form a sensing component for the fabric article 100. The three conductive regions 107, 109, 111 are provided between the first section 113 and the second section 115 of the base component 101.

The sensing component is part of the continuous body of fabric. This means that the sensing component is integrally formed with the base component 101. The sensing component is formed from conductive yarn, and in particularly is a unitary knitted structure formed from a single length of conductive yarn. This means that separate wires, connectors or other hardware elements are not required to electrically connect the different parts of the sensing component together.

The first conductive region 107 extends along the second surface 104 of the base component 101. The first conductive region 107 is formed as a result of the knitting of conductive yarn on the front bed 3 in steps S101-5103 and steps S106-S108. The first conductive region 107 is provided proximate to the end region 103.

The second conductive region 109 extends along the first surface 102 of the base component 101 and is provided proximate to the end region 105. The second conductive region 109 is formed as a result of the knitting of conductive yarn on the back bed 5 in steps S98-S101 and steps S108-S111.

The third conductive region 111 extends along the second surface 104 of the base component 101. The third conductive region 111 is formed as a result of the knitting of conductive yarn on the front bed 3 in steps 3101 and S108.

The first conductive region 107 forms a connection region 107 for electrically connecting with a removable electronics module 300 (explained above in relation to Figure 19). In particular, a conductive interface element 311 of the electronics module 300 is able to contact the connection region 107 to electrically connect the electronics module 300 to the connection region 107.

The first conductive region 107 is a three-dimensional conductive region 107 that extends away from the second surface 104 along the Z axis as shown in Figure 20C.

The first conductive region 107 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the second surface 104 of the base component 101. The remaining courses of conductive yarn extend away from the second surface 104 of the base component 101 to form the raised conductive region 107.

The second conductive region 109 forms an electrode for monitoring activity at a body surface.

The second conductive region 109 is a three-dimensional conductive region 109 that extends away from the first surface 102 along the Z-axis as shown in Figure 20C. This threedimensional/raised conductive region 109 forms a three-dimensional/raised electrode 109 for contacting the skin surface of the wearer to measure signals from the wearer and/or introduce signals into the wearer. The second conductive region 109 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the first surface 102 of the base component 101. The remaining courses of conductive yarn extend away from the first surface 102 of the base component 101 to form the raised conductive region 109.

The electrode 109 may be arranged to measure one or more biosignals of a user wearing the fabric article 100. Here, "biosignal" may refer to any signal in a living being that can be measured and monitored. The electrode 109 is generally for performing bioelectrical or bioimpedance measurements. Bioelectrical measurements include electrocardiograms (ECG), electrogastrograms (EGG), electroencephalograms (EEG), and electromyography (EMG).

Bioimpedance measurements include plethysmography (e.g., for respiration), body composition (e.g., hydration, fat, etc.), and electroimpedance tomography (EIT). The electrode 109 may additionally or separately be used to apply an electrical signal to the wearer. This may be used in medical treatment or therapy applications.

The third conductive region 111 forms a conductive pathway 111 that electrically connects the first conductive region 107 to the second conductive region 109. The conductive pathway 111 is substantially flush with (or extends to a lesser extent than the first or second conductive regions 107, 109) the second surface 104 of the base component 101 (Figure 20C) and is formed from one or more (two in this example) of courses of conductive yarn extending between adjacent courses of non-conductive yarn in the base component 101. Proximate to the second conductive region 109, part of the conductive yarn extends through the base component 101 so as to be electrically connected to the second conductive region 109 provided on the first surface 102.

The first conductive region 107 and the second conductive region 109 are spaced apart from one another along the length of the fabric article 100. That is, they are spaced apart along the X-axis (Figures 18A and 18B) The first conductive region 107 is provided proximate to the end region 103 of the base component 101 that forms the valley.

The second conductive region 109 is provided proximate to the end region 105 of the base component 101 that forms the peak.

The fabric article 100 that can be manufactured integrally in a single knitting operation is therefore provided. This means that discrete electronic components do not need to be integrated into an already formed base component but instead the sensing component is formed of conductive yam as the base component is being knitted. The resultant fabric article has a singular fabric structure which handles, feels, behaves and looks like a fabric while providing the desired sensing functionality.

The construction of fabric article 100 in Figures 20A to 20C provides the electrode 109 and connection region 107 on opposed surfaces 102, 104 of the base component 101. This is not required in all examples of the present disclosure as, in some examples, the electrode 109 and the connection region 107 may be provided on the same surface of the base component 101.

The conductive regions 107, 109, 111 further comprise a filler material disposed therein. The filler material is integral with the continuous body of fabric and in particular comprises an expanding yarn. During the knitting operation for forming the continuous body of fabric, the expanding yarn is intruded into the conductive regions 107, 109, 111.

Beneficially, the filler material raises the profile of the conductive regions 107, 109 away from the base component 101. This helps to increase the quality, consistency and area of contact area. This is particularly beneficial for the raised electrode 109 as it helps ensure contact against the skin surface without requiring the fabric article 100 to provide additional compression such as through additional elastomeric material. The filler material maintains the shape of the raised conductive regions 107,109 and protects against deformation, buckle and roll even when they are rubbed against the skin or other surface. Moreover, using an expanding yarn means that the process of filling out the conductive regions 107, 109 is an intrinsic part of the manufacturing process. A separate manual process of inserting filler material into already formed conductive regions 107, 109 is not required.

The base component 101 in this example has a racked-rib structure and is thus knit using tuck-rib stitches which are formed using tuck stitches on one needle bed complemented by knitting stitches on the other needle bed. The stitches may be knitted in a two-course repeat manner. The tuck-rib stitches used to form a racked-rib structure are often referred to as full-cardigan stitches.

The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border this results in larger gaps between the stitches.

Advantageously, knitting the base component 101 using cardigan stitches means that the base component 101 has larger gaps between stitches as compared to other knitting techniques such as just using knitted loops on both needle beds or an interlock knitting technique. These larger gaps enable the base component 101 to accommodate thicker conductive yarn. Thicker conductive yarn is advantageous as it is less likely to break and is more resistant to washing. Fabric articles with thicker conductive yarn can typically be washed a greater number of times without the measured impedance increasing beyond and acceptable value.

Yarn thickness may be measured using its yarn count. Yarn count is a measure of the total length per weight of yarn. The yarn count measures include Cotton Count (cc) which gives a measure of the number of 840 yard units in a pound of yam, Worsted Count (wc) which gives a measure of the number of 560 yard units in a pound of yarn, and Numero Metric Count (nm) which gives a measure of the number of 1000 metre units in a kilogram of yarn.

Yarn counts are typically represented in the form XJY, where X is the yarn count for a single ply of yam and Y is the number of piles that make up the yarn. The number X is divided by Y to give the final yarn count.

For example, a yarn may have a yarn count of 30/2 nm which means that each ply has a yarn count of 30 and that there are two plies that make up the yarn. The final yarn count is 15 nm which means that there are 15000 metres of yarn per kilogram.

Another yarn may have a yarn count of 20/2 nm which means that each ply has a yarn count of and that there are two plies that make upthe yarn. The final yarn count is 10 nm which means that there are 10000 metres of yarn per kilogram.

A yarn with a lower yarn count in nm is therefore heavier per unit length and thicker than a yarn with a higher yarn count In some examples, a yarn with a yarn count of 15nm or higher is thin enough that it can fit through the gaps in a base component regardless of the knitting technique used to manufacture the base component, e.g. knit using both needle beds simultaneously or using an interlock technique. However, yarns with yam counts lower than this value may be more challenging to fit through the gaps between stitches in the base component. This can increase the complexity of the knitting process and reduce the appearance and performance of the resultantly formed fabric article.

Advantageously, knitting the base component 101 using cardigan stitches results in larger gaps between the knitted stitches which allows for conductive yarns with a yarn count of less than 15nm to be intermeshed with the base component.

Moreover, using cardigan stitches result in a base component 101 with a reduced weight as cardigan stitches use less yarn and are lighter than other knit structures. This enables a wider base component 101 to be knitted for the same weight/amount of yarn. Moreover, the knitting process for forming a base component 101 using cardigan stitches is faster than other knitting techniques such as interlock which enables the fabric article 100 to be manufactured more quickly. Therefore, forming the base component using cardigan stitches reduces the time required to knit the fabric article.

In preferred examples, the base component 101 is knit using cardigan stitches and the conductive yarn has a yam count of less than 15nm. The yarn count may be less than 14nm, less than 13nm, less than 12nm, less than 11m. The yarn count may be greater than 5nm, greater than 6nm, greater than 7nm, greater than 8nm, or greater than 9nm. The yam count may be between 8nm and 12nm and is preferably 10 nm (e.g. a yarn with a yarn count of 20/2 nm). The conductive yarn in this example is preferably a stainless-steel yarn Figures 21A-21B show another example fabric article 100 according to aspects of the present disclosure. The fabric article 100 has a similar construction to the fabric article 100 of Figures 20A to 20C and like reference numerals are used to indicate like components.

In this example, the edges 103a, 103b of the end region 103 form a valley rather than a peak as per the example of Figures 20A to 20C and the edges 105a, 105b of the end region 105 form a peak rather than a valley as per the example of Figures 20A to 20C.

Referring to Figure 22, there is shown an assembly 200 comprising two of the fabric articles 100 shown in Figures 20A-20C. The assembly 200 further comprises a fabric layer 201 which may be a fabric layer of a wearable article such as a garment.

The fabric articles 100 are attached to the fabric layer 201 such as by bonding so that the end regions 103 are positioned proximate to one another. The positioning of the fabric articles 100 is similar to the example of Figure 18. However, the tapered end regions 103 result in the formation of gaps 'G' between the two base components 101 and minimises the amount of base component 101 for the two fabric articles 100 that are close to one another/touching. In this example, there is a single point at the apex of the two peaks of the end regions 103 that contacts/is close to the other base component 101. This reduces the possibility of a moisture bridge being formed between the two connection regions 107 and thus reduces the possibility of an electrical short being formed between the contact pads 311 of an electronics module 300 positioned on the assembly 200.

Referring to Figure 23, there is shown an assembly 200 comprising two of the fabric articles 100 shown in Figures 21A-21B. The assembly 200 further comprises a fabric layer 201 which may be a fabric layer of a wearable article such as a garment.

The fabric articles 100 are attached to the fabric layer 201 such as by bonding so that the end regions 103 are positioned proximate to one another. The positioning of the fabric articles 100 is similar to the example of Figure 18. However, the tapered end regions 103 result in the formation of a gap 'G' between the two base components 101 and minimises the amount of base component 101 for the two fabric articles 100 that are close to one another/touching. In this example, a single gap 'G' is formed by the two valleys of the end regions 103. This reduces the possibility of a moisture bridge being formed between the two connection regions 107 and thus reduces the possibility of an electrical short being formed between the contact pads 311 of an electronics module 300 positioned on the assembly 200.

In some examples, waterproofing material may be provided in the gaps G formed between the base components 101 to further reduce the likelihood of a moisture bridge being formed between the two connection regions 107. The waterproofing material may be a silicone material such as a silicone film. Figure 24 shows two waterproofing regions 117 provided in the gaps G formed between the base components 101 in the example of Figure 22. Figure 25 shows a single waterproofing region 117 provided in the gap G formed between the base components 101 in the example of Figure 23.

Referring to Figures 26A-26D, there is shown an example knitting notation diagram for knitting a fabric article 100 in accordance with aspects of the present disclosure. The fabric article 100 may be any of the fabric articles 100 shown in Figures 20 to 25. It will be appreciated that the fabric article 100 may comprise a greater number of stitches and courses than the simplified diagrams shown in Figures 26A-26D. The example of Figures 26A to 26D only shows a small number of courses and stitches for simplicity.

The knitting notation diagram shows a series of knitting operations used to form, in sequence, the first section 113 of the base component 101, the conductive regions 107, 109, 111, and the second section 115 of the base component 101.

The base component 101 is a region formed entirely or predominantly from non-conductive yarn and serves as a base on which conductive regions are provided. The resultantly formed base component 101 has a racked-rib structure.

The knitting operations S91-S96 comprise knitting a plurality of courses of non-conductive yarn using tuck-rib stitches while selectively racking one of the front and back needle beds 3, 5 relative to the other of the front and back needle beds 3, 5. In this and other examples described herein, the back needle bed 5 is the only bed that is racked. This is because the front needle bed 3 is fixed for most, but not all, knitting machines. Of course, the front needle bed 3 may be racked if the knitting machine supports this operation.

In this example, the non-conductive base fabric yarn is a composite fabric elastomeric yarn. In particular, a composite fabric elastomeric yarn comprising 81% nylon and 19% elastane is used.

Of course, other non-conductive yarns may be used as desired by the skilled person. The nonconductive base component 101 may comprise additional yarns which may be incorporated during the knitting of the base component 101.

The knitting operations 591-596 form pairs (591, S92), (593, 594), (595, 596). It will be noted that the pairs (S91, 392), (393, S94), (895, S96) use a full-cardigan style sequence. This means that the second course in each pair uses the reverse of the knitting stitches used for the first course in each pair.

For each pair, one of the knitted courses (S91, 393, S95) comprises tuck stitches on the front bed 3 and knitted loops on the back bed 5. The other knitted course in the pair (S92, 394, S96) uses the reverse of the knitting sequence used for the first course in the pair (S91, S93, S95) and thus comprises knitted loops on the front bed 3 and tuck stitches on the back bed 5.

The position of one of the needle beds (the back bed 5 in this example) moves from a first position when knitting the first course (S91, S93, S95) to knitting the second course in the pair (392, 394, 396). In this example, the back needle bed 5 is racked to the left during the knitting of the first course (391, 393, 395) in each pair such that the back bed 5 is not aligned with the front bed 3. During the knitting of the other course (392, 394, 396) the back bed 5 is racked back to the right such that it aligned with the front bed 3. Of course, if desired, the racking could be performed to the right and could be performed on the second course in each pair (S92, S94, 396) rather than the first course in each pair (391, 393, 395).

The knitting operations S91-S96 result in the formation of the first section 113 of the base component 101 of the fabric article 100. As a result of the use of tuck-rib stitches with selective racking of the needle beds, causes the first section to have wales extending in a first direction. The first direction is generally not perpendicular to the course direction. This forms the edges 103a, 105a as shown in Figure 20A for example.

While the drawings show a rack to the left by one needle tick for every other course, racking by more than one needle tick can also be performed depending on the properties of the knitting machine used. Further, racking in a different direction and a different sequence of racking operations can be used to produce different geometrical effects in the base component.

S97 shows the knitting of a course of non-conductive yarn using knitted loops on both needle beds without racking. This layer of double-knit yarn balances out the racked-rib structure and is not required in all examples of the present disclosure.

Figures 26B and 26C show knitting operations S98-S111 used to form conductive regions 107, 109, 111 that are attached to the base component. The knitting operations are performed without racking of the needle beds 3, 5. The conductive yarn is held on a different yarn carrier to the non-conductive yarn used to knit the base component.

The conductive yarn may be a stainless-steel yarn such as those manufactured by TIBTECH Innovations. The conductive yarn may be a silver coated yarn such as the Circuitex TM conductive yam from Noble Biomaterials Limited. Of course, other conductive yarns may be used. The conductive yarn may comprise a non-conductive or less conductive base yam which is coated or embedded with conductive material such as carbon, copper and silver.

398-3100 comprise knitting three courses of conductive yarn using knitted loops on the back needle bed 5 only to form part of a second conductive region 109. The course knitted in step 898 is intermeshed with the previous course of non-conductive yarn used to form the base component 101 such that the second conductive region 109 is attached to the base component 101 The additional courses knit in 899 and 8100 are performed using the back bed 5 only and because of this, the opposite needles on the front bed 3, which are not used for knitting, are not able to balance out the knit layers. This causes the conductive yarn to bunch-up on the back-needle bed. This forms a three-dimensional structure in the finished fabric article. This three-dimensional structure may form an elongate tubular shape.

The number of courses is not required to be three and can instead be any number greater than or equal to one. Even with a limited number of courses, the 3D profile of the conductive region can still be provided by introducing the filler yam as explained below.

S101 comprises knitting a course of conductive yarn comprising a sequence of knitted loops on the back needle bed Sand a sequence of knitted loops on the front needle bed 3.

The knitted loops on the back needle bed 5 continue the knitting of the second conductive region 109. The knitting on the front needle bed 3 forms part of the third conductive region 111 and the first conductive region 107. In effect, the transition from knitting on the back bed 5 to the front bed 3 pulls the conductive yarn through the base component 101.

S102-S103 comprise knitting two courses of conductive yarn using knitted loops on the front needle bed 3 only. This continues the formation of the first conductive region 107. Because the conductive yarn is knitted using the front bed 3 only, the back bed 5 is not able to balance out the knit layers. This causes the conductive yarn to bunch-up to create a three-dimensional structure. This three-dimensional structure may form an elongate tubular shape.

Step S104 and 5015 comprise knitting courses of filler yam using tuck stitches separated by float stitches. The course of filler yarn comprises a sequence of tucks and floats on the front bed 3 and a sequence of tucks and floats on the back bed 5.

Tuck knitting operations result in the formation of an extra stitch behind an existing stitch. The extra stitch is not visible from the outside surface of the fabric article. The tuck stitch is used to layer-in the filler yarn behind the conductive regions so that it is not visible from the outside of the fabric article.

The filler yarn in this example is an expanding yarn. The expanding yarn may refer to a yarn that expands under the application of an external stimulus such as heat, pressure or steam. Preferably the yarn expands under the application of steam. The expanding yarn may comprise a polyester material and may be a polyester filament yarn. The expanding yarn used in this example is a Newlife TM polyester filament yarn manufactured by Sinterama S.p.A.

Beneficially, the use of an expanding yarn means that after the fabric article is constructed, steam (for example) may be applied to cause the yarn to expand and bulk out the shape of the conductive regions 107, 109, 111 and provide further stability. It is particularly desired to bulk out the first and second conductive regions 107 and 109. The third conductive region 111 is bulked out to a lesser extent due to the fewer number of knit courses used to make the second conductive region 109.

As the expanding yarn expands to fill the space between the conductive regions 107, 109, 111 and the base component 101, the space between the conductive regions 107, 109, 111 and the base component 101 does not need to be densely packed with filler material during the knitting operation. Less yarn is required than if a non-expanding filler material were used. For example, a single strand of expanding yam may provide the necessary support and stability function when the steam (for example) is applied.

The filler yarn provides a stabilising function for the conductive regions 107, 109, 111 in order to reduce noise and other electronic artefacts. The filer yarn urges the profile of the conductive regions 107, 109, 111 out from the base component 101 and increase the quality, consistency and area of contact for the electrode 109 against the skin surface and the connection region 107 against the electronics module 300 (described above). This is provided without requiring an increase in the amount of compression applied to the skin surface by the fabric article 100. Moreover, as the expanding yarn is integrally knit with the remainder of the fabric article 100, this simplifies the manufacturing process and avoids the need to separately insert filler material after the continuous body of fabric is formed.

The filler yarn is knit using front bed 3 knitting in regions where the conductive yarn is knit using the back bed 5 (the second conductive region 109). The filler yarn is knit using back bed 5 knitting in regions where the conductive yarn is knit using the front bed 3 (the first and third conductive regions 107, 111). This is performed so as to anchor the filler yarn on the base component 101 rather than the conductive regions 107, 109, 111. This is particularly desirable when an expanding yarn is used as a filler yarn as it helps ensure that the expanding yarn pushes against and urges the conductive regions 107, 109, 111 away from the base component 101 to form the desired three-dimensional shapes.

Steps 5106 and 3107 comprise knitting further courses of the first conductive region 107 using the front needle bed 3.

Step S108 comprises knitting the final course of the first conductive region 107 and the third conductive region 111 using the front needle bed 3 and a further course of the second conductive region 109 using the back needle bed 5.

Steps 3109-S111 comprise knitting the final courses of the second conductive region 109 using the back needle bed 5 only.

Figure 26D shows knitting operations 3112-3118 used to knit a further part of the base component having a racked-rib structure.

Step S112 comprises knitting a course of non-conductive yarn using both front and back needle beds without racking to close off the conductive yarn regions knit in steps S98 to S111.

Steps S113-S118 comprise knitting a plurality of pairs of courses (S113, S114), (S115, S116), (S117, S118) of non-conductive yarn using tuck-rib stitches while selectively racking the back bed 5 relative to the front bed 3.

A second sequence of tuck-rib stitches is used which is different to the first sequence used to knit the first section of the base component in steps 391 to 396. The second sequence of tuck-rib stitches is the reverse of the first sequence such that knitting operations performed on the front bed 3 in the first sequence are performed on the back bed 5 in the second sequence. Moreover, knitting operations performed on the back bed 5 in the first sequence are performed on the front bed 3 in the second sequence.

The knitting operations 5113-5118 form pairs (S113, S114), (8115, 5116), (S117, S118). It will be noted that the pairs (8113, S114), (S115, 8116), (8117, S118) use a full-cardigan style sequence. This means that the second course in each pair uses the reverse of the knitting stitches used for the first course in each pair.

For each pair, one of the knitted courses (S113, S115, S117) comprises knitted loops on the front bed 3 and tuck stitches on the back bed 5. The other knitted course in the pair (3114,3116, 8118) uses the reverse of the knitting sequence used for the first course in the pair (S113, S115, S117) and thus comprises tuck stitches on the front bed 3 and knitted loops on the back bed 5.

The position of one of the needle beds (the back bed 5 in this example) moves from a first position when knitting the first course (3113, 3115, 3117) to knitting the second course in the pair (3114, S116, S118). In this example, the back needle bed 5 is racked to the left during the knitting of the first course (8113, S115, S117) in each pair such that the back bed 5 is not aligned with the front bed 3. During the knitting of the other course (S114, S116, S118) the back bed 5 is racked back to the right such that it aligned with the front bed 3. Of course, if desired, the racking could be performed to the right and could be performed on the second course in each pair (3114, 3116, S118) rather than the first course in each pair (5113, 8115, S117).

The knitting operations 3113-S118 result in the formation of a second section of the base component of the fabric article. As a result of the use of tuck-rib stitches with selective racking of the needle beds, causes the second section to have wales extending in a second direction different from the first direction. The second direction is generally not perpendicular to the course direction. This forms the edges 103b, 105b as shown in Figure 20A for example.

Importantly, the wales of the first section 113 of the base component 101 extend in a first direction and the wales of the second section 115 of the base component 101 extend in a second direction, different from the first direction, this results in the formation of a peak or valley along an edge of the base component in the wale direction. This results in the formation of the tapered end regions 103, 105 as explained above.

It will be appreciated that the above diagram is only a simplified example of knitting operations that may be performed according to aspects of the present disclosure.

Some or all of the sections may comprise more or a different number of stitches. The number of stitches determines the length of the sections and longer or shorter sections may be knitted as desired.

The number of courses of yam used to knit the base component 101 may be varied as appropriate by the skilled person so as to vary the width of the base component 101 in the finished fabric article 100. More or fewer knit courses may be provided. The racking effect can be continued by continuing to knit pairs of courses, e.g. (S91, S92), using the knitting sequences and racking shown in the drawings.

While the base component 101 is knit using only one-type of non-conductive yarn in the example. Additional yarns may be used in knitting the base component if desired. Other example yarns include elastomeric yams to add further stretch to the base component.

Moreover, additional stitches other than tuck-rib stitches may be used for the base component 101. For example, in addition to the tuck-rib stitches and double-knit stitches shown in the diagram other courses may be knit using techniques such as interlocking to impart additional desired properties for the base component 101.

The conductive regions 107, 109, 111 do not need to be knitted using tuck-rib stitches and racking does not need to be used during the knitting of the conductive yarn. Instead, conventional knitting using knitted loops on one or both of the front and back needle beds 3, 5 may be used as shown in the diagrams.

The first, second, and third conductive regions 107, 109, 111 are not required to have the number of stitches or courses shown in the Figures. A greater number of courses can be knit to increase the three-dimensional effect of any or all ofthe conductive regions 107, 109, 111. Fewer courses can also be knit to reduce the three-dimensional effect of any or all of the conductive regions 107, 109, 111.

The filler yarn while beneficial for enhancing the 3D effect of the conductive regions 107, 109, 111 is not required in all examples. The filler yarn may be omitted from any or all of the conductive regions 107, 109, 111.

The first conductive region 107 is not required to be knit using the front needle bed 3 and could be knit using the back needle bed 5.

The second conductive region 109 is not required to be knit using the back needle bed 5 and could be knit using the front needle bed 3.

The third conductive region 111 is not required to be knit using the front needle bed 3 and could be knit using the back needle bed 5.

The second and third conductive regions 109, 111 could be knit using the back needle bed 5 while the first conductive region 107 could be knit using the front needle bed 3 or vice versa.

The first and second conductive regions 107, 109 could be knit using the back needle bed 5 while the third conductive region 111 could be knit using the front needle bed 3 or vice versa.

The first, second and third conductive regions 107, 109, 111 could all be knit using the front needle bed 3 or the back needle bed 5.

The knitting of the conductive regions 107, 109, 111 is not required to only use knitted loops as shown in the Figures additional stitches such as float stitches may be used if desired.

In the above examples, the two fabric articles 100 are provided as separate articles. This is not required in all aspects of the present disclosure and the fabric articles 100 may be attached to one another/integrally formed with one another.

Figure 27 shows two fabric articles 100 according to the example of Figures 20A-20C. The end regions 103 are joined by fabric material 119.

Figure 28 shows two fabric articles 100 according to the example of Figures 21A-21B. The end regions 103 are joined by two fabric material regions 119.

The fabric articles 100 of Figures 26 and 27 may be integrally knit. This may involve using two separate yarn carriers for knitting the two base components 101 of the fabric articles 100. One of the fabric articles 100 may be knit using one of the yarn carriers while the other fabric article 100 is knit using the other yarn carrier. Knitting may be performed using both yarn carriers to form the fabric material 119 that joins the two articles 100 together.

The present disclosure is not limited to electronics modules 300 (Figure 19) that communicate with mobile devices and instead may communicate with any electronic device capable of communicating directly with the electronics module 300 or indirectly via a server over a wired or wireless communication network. The electronic device may be a wireless device or a wired device. The wireless/wired device may be a mobile phone, tablet computer, gaming system, MP3 player, point-of-sale device, or wearable device such as a smart watch. A wireless device is intended to encompass any compatible mobile technology computing device that connects to a wireless communication network, such as mobile phones, mobile equipment, mobile stations, user equipment, cellular phones, smartphones, handsets or the like, wireless dongles or other mobile computing devices. The wireless communication network is intended to encompass any type of wireless network such as mobile/cellular networks used to provide mobile phone services.

The present disclosure is not limited to the use of pockets for releasably mechanically coupling the electronics module 300 to the wearable article/assembly and other mounting arrangements for the electronics module 300 are within the scope of the present disclosure. The mechanical coupling of the electronic module 300 to the wearable article may be provided by a mechanical interface such as a clip, a plug and socket arrangement, etc. The mechanical coupling or mechanical interface may be configured to maintain the electronic module 300 in a particular orientation with respect to the wearable article when the electronic module 300 is coupled to the wearable article. This may be beneficial in ensuring that the electronic module 300 is securely held in place with respect to the wearable article and/or that any electronic coupling of the electronic module 300 and the wearable article (or a component of the wearable article) can be optimized. The mechanical coupling may be maintained using friction or using a positively engaging mechanism, for example.

Beneficially, the removable electronic module 300 may contain all of the components required for data transmission and processing such that the wearable article only comprises the sensing components. In this way, manufacture of the wearable article may be simplified. In addition, it may be easier to clean a wearable article which has fewer electronic components attached thereto or incorporated therein. Furthermore, the removable electronic module 300 may be easier to maintain and/or troubleshoot than embedded electronics. The electronic module 300 may comprise flexible electronics such as a flexible printed circuit (FPC). The electronic module 300 may be configured to be electrically coupled to the wearable article.

It may be desirable to avoid direct contact of the electronic module 300 with the wearer's skin while the wearable article is being worn. It may be desirable to avoid the electronic module 300 coming into contact with sweat or moisture on the wearer's skin. The electronic module 300 may be provided with a waterproof coating or waterproof casing. For example, the electronic module 300 may be provided with a silicone casing.

The electronics module 300 may further comprise a power source (not shown). The power source is coupled to the controller 309 and is arranged to supply power to the controller 309. The power source may comprise a plurality of power sources. The power source may be a battery. The battery may be a rechargeable battery. The battery may be a rechargeable battery adapted to be charged wirelessly such as by inductive charging. The power source may comprise an energy harvesting device. The energy harvesting device may be configured to generate electric power signals in response to kinetic events such as kinetic events performed by a wearer of the garment. The kinetic event could include walking, running, exercising or respiration of the wearer. The energy harvesting material may comprise a piezoelectric material which generates electricity in response to mechanical deformation of the converter. The energy harvesting device may harvest energy from body heat of a wearer of the garment. The energy harvesting device may be a thermoelectric energy harvesting device. The power source may be a super capacitor, or an energy cell.

The electronics module 300 may further comprise a communicator (not shown) for communicating with an external device such as a mobile device. The communicator may be a mobile/cellular communicator operable to communicate the data wirelessly via one or more base stations. The communicator may provide wireless communication capabilities for the wearable article and enables the wearable article to communicate via one or more wireless communication protocols such as used for communication over: a wireless wide area network (kW/AN), a wireless metroarea network (WMAN), a wireless local area network (WLAN), a wireless personal area network (VPAN), Bluetooth ® Low Energy, Bluetooth 0 Mesh, Bluetooth ® 5, Thread, Zigbee, IEEE 802.15.4, Ant, a near field communication (NFC), a Global Navigation Satellite System (GNSS), a cellular communication network, or any other electromagnetic RF communication protocol.. The cellular communication network may be a fourth generation (4G) LTE, LTE Advanced (LTE-A), LTE Cat-M1, LTE Cat-M2, NB-loT, fifth generation (5G), sixth generation (6G), and/or any other present or future developed cellular wireless network. A plurality of communicators may be provided for communicating over a combination of different communication protocols.

The electronics module 300 may comprise an input unit (not shown). The input unit enables the electronics module 300 to receive a user input for controlling the operation of the electronics module 300. The input unit may be any form of input unit capable of detecting an input event.

The input event is typically an object being brought into proximity with the electronics module 300.

In some examples, the input unit comprises a user interface element such as a button. The button may be a mechanical push button.

In some examples, the input unit comprises an antenna. In these examples, the input event is detected by a current being induced in the first antenna. The mobile device is powered to induce a magnetic field in an antenna of the mobile device. When the mobile device is placed in the magnetic field of the antenna, the mobile device induces current in the antenna.

In some examples, the input unit comprises a sensor such as a proximity sensor or motion sensor. The sensor may be a motion sensor that is arranged to detect a displacement of the electronics module 300 caused by an object being brought into proximity with the electronics module 300. These displacements of the electronics module 300 may be caused by the object being tapped against the electronics module 300. Physical contact between the object and the electronics module 300 is not required as the electronics module 300 may be in a holder such as a pocket of the wearable article. This means that there may be a fabric (or other material) barrier between the electronics module 300 and the object. In any event, the object being brought into contact with the fabric of the pocket will cause an impulse to be applied to the electronics module 300 which will be sensed by the sensor.

It will be appreciated that a physical coupling between the electronics module 300 and the connection regions 107 is not required in all examples. The connection regions 107 may couple to a communication interface of the wearable article such as an inductive coil. The electronics module 300 may comprise a corresponding inductive coil to allow for inductive communication between the wearable article and the electronics module 300.

In some examples of the present disclosure, the fabric article 100 further comprises a gripper component provided on the first surface 102 of the base component 101. The gripper component is arranged to grip the fabric article to the skin surface and hold it in place even when the wearer of the fabric article is moving.

The above examples refer to forming tapered end regions 103, 105 (Figure 20A) as an inherent part of a well knitting process. While this is preferred, it is not required in all examples. For example, the tapered end regions 103, 105 could be formed after the fabric article is knitted by cutting or otherwise removing material from the end regions 103, 105. In such examples, the fabric article is not required to be weft knitted and could be warp knitted or woven for example.

Forming the tapered end regions 103, 105 as an integral part of the knitting process as described in the above examples is preferred at least because it reduces the amount of manufacturing steps involved.

At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as 'component', 'module' or 'unit' used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term "comprising" or "comprises" means including the component(s) specified but not to the exclusion of the presence of others.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

37 CLAIMS 1. A method of welt knitting a fabric article using a knitting machine comprising first and second needle beds, the method comprising: knitting a first plurality of courses of yarn using a first sequence of tuck-rib stitches while selectively racking one of the first and second needle beds relative to the other of the first and second needle beds to form a first section of a base component with wales extending in a first direction; knitting conductive yarn to form a first conductive region that is connected to the first section of the base component; knitting a second plurality of courses of yarn to form a second section of the base component that is connected to the first conductive region and the first section of the base component, the knitting comprises using a second sequence of tuck-rib stitches while selectively racking one of the first and second needle beds relative to the other of the first and second needle beds, wherein the second section of the base component has wales extending in a second direction different from the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, and wherein the first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.
2. A method as claimed in claim 1, wherein the second sequence is the reverse of the first sequence such that stitches performed on the first bed for the first sequence are performed on the second bed for the second sequence, and stitches performed on the second bed for the first sequence are performed on the first bed for the second sequence.
3. A method as claimed in claim 1 or 2, wherein knitting the first plurality of courses comprises knitting a plurality of pairs of courses, wherein knitting each pair comprises: knitting a first course while the first and second beds are in a first position; knitting a second course while one of the first and second beds is racked relative to the other of the first and second beds so as to move the one of the first and second beds away from the first position.
4. A method as claimed in claim 3, wherein the second course comprises the reverse of the stitches used for the first course such that stitches performed on the first bed for the first course are performed on the second bed for the second course, and stitches performed on the second bed for the first course are performed on the first bed for the second course.
5. A method as claimed in any preceding claim, wherein knitting the second plurality of courses comprising knitting a plurality of pairs of courses, wherein knitting each pair comprises: knitting a first course while the first and second beds are in a first position; knitting a second course while one of the first and second beds is racked relative to the other of the first and second beds so as to move the one of the first and second beds away from the first position.
6. A method as claimed in claim 5, wherein the second course comprises the reverse of the stitches used for the first course such that stitches performed on the first bed for the first course are performed on the second bed for the second course, and stitches performed on the second bed for the first course are performed on the first bed for the second course.
7. A method as claimed in any preceding claim, wherein knitting the conductive yarn to form the conductive region comprises knitting a plurality of courses of conductive yarn using one of the first and second beds to form a raised conductive region that extends away from a surface of the base component.
8. A method as claimed in claim 7, further comprising knitting at least one course of filler yarn using tuck stitches such that the filler yarn is deposited within a space formed between the first conductive region and the base component.
9. A method as claimed in any preceding claim, wherein knitting the conductive yarn further comprising forming a second conductive region that is connected to the first and second sections of the base component.
10. A method as claimed in claim 9, wherein the first and second conductive regions are spaced apart from one another.
11. A method as claimed in claim 9 or 10, wherein the first conductive region is knitted using the first bed and the second conductive region is knitted using the second bed such that the first and second conductive regions are provided on opposing surfaces of the base component.
12. A method as claimed in any of claims 9 toll, wherein knitting the conductive yarn further comprises forming a third conductive region that is connected to the first and second sections of the base component, wherein the third conductive region electrically connects the first conductive region to the second conductive region.
13. A method as claimed in any preceding claim, wherein the base component and the conductive region form a continuous body of weft knitted fabric.
14. A method as claimed in any preceding claim, wherein the first conductive region forms a connection terminal for electrically connecting with an electronics module.
15. A computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine comprising a first bed and a second bed, are operable to cause the computer to control the knitting machine to perform the method as claimed in any preceding claim.
16. A weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive region formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component, wherein the first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.
17. An assembly comprising: a first weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive region formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component, wherein the first conductive region is located proximate to the edge of the base component in which the peak or valley is formed; a second weft knitted fabric article comprising: a base component comprising a racked-rib structure, the racked-rib structure comprising a first section with wales extending in a first direction and a second section with wales extending in a second direction different to the first direction such that a peak or valley is formed along an edge of the base component in the wale direction, the base component comprising tuck-rib stitches; and a first conductive region formed from conductive yarn, the first conductive region is connected to the first and second sections of the base component, wherein the first conductive region is located proximate to the edge of the base component in which the peak or valley is formed.
18. An assembly as claimed in claim 17, further comprising a fabric layer, wherein the first and second fabric articles are attached to the fabric layer such that the first conductive regions are located proximate to one another 20 25 30