GB2608385A

GB2608385A - Circuit board assemblies for inclusion within garments

Info

Publication number: GB2608385A
Application number: GB2109345.5A
Authority: GB
Inventors: Kar-Chun Wong Jason
Original assignee: Wearable Technology Ltd; Wearable Technologies Ltd
Current assignee: Wearable Technologies Ltd
Priority date: 2021-06-29
Filing date: 2021-06-29
Publication date: 2023-01-04
Also published as: GB202109345D0

Abstract

A wiring loom is shown for inclusion within an item of clothing. The loom is constructed from individual circuit boards (101, 102) with electrically conducting wires (111, 112) connecting the circuit boards together to form a loom with an interface terminal (116). A protective moulding (131) encases the circuit board, such that each circuit board includes at least one electrically connected component, such as a light emitting device (121) or a peripheral device connector (131). The moulding is cut through extended portions (142, 143) provided on both sides of each circuit board. Preferably the extended portions of the mouldings are stitched into the garment on assembly. At least one of the circuit boards may comprise light emitting elements such as LEDs. Also claimed is a method of manufacture in which the protective molding is overmoulded.

Description

Circuit Board Assemblies for Inclusion within Garments

CROSS REFERENCE TO RELATED APPLICATIONS

This is the first application for a patent directed towards the invention and the subject matter.

BACKGROUND OF THE INVENTION

The present invention relates to an apparatus for inclusion within an item of clothing. The present invention also relates to a method of constructing an apparatus for inclusion within an item of clothing. An example of clothing for operatives working in hazardous environments is shown in GB 2 543 423, assigned to the present applicant. Items of clothing worn on the upper torso, including jackets, vests and harnesses etc., are provided with light-emitting devices powered and controlled from a central control unit and connected together by means of a wiring loom. In addition to the light-emitting devices, other electrical components may be connected to the loom and additional interface devices may be provided. For example, a light detection device may be included, as described in GB 2 552 134, assigned to the present applicant. Jackets of this type may be produced by effectively retrofitting electronic components to an existing garment. However, for mass-producing garments of this type, the inventor has appreciated that it is desirable to construct a loom subassembly at a facility competent in the handling of electronic components.

Thereafter, advantages are to be gained by incorporating the loom within a garment during the construction of the garment itself. However, it is also appreciated that this procedure is best performed within an environment having an expertise in the production of fabric garments.

It has also been appreciated that a transportation problem exists in terms of moving loom subassemblies and it has been found desirable to construct a unified block of circuits which are then cut into individual items prior to garment assembly. However, this approach has introduced a further problem in that after being cut, an edge may be presented that is susceptible to water ingress, particularly during a washing cycle.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided an apparatus for inclusion within an item of clothing, as set out in claim 1. According to a second aspect of the present invention, there is provided a method of constructing an apparatus for inclusion within an item of clothing, as set out in claim 8.

Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings. The detailed embodiments show the best mode known to the inventor and provide support for the invention as claimed. However, they are only exemplary and should not be used to interpret or limit the scope of the claims. Their purpose is to provide a teaching to those skilled in the art. Components and processes distinguished by ordinal phrases such as "first" and "second" do not necessarily define an order or ranking of any sort.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Figure 1 shows an apparatus for inclusion within an item of clothing; Figure 2 shows a cross sectional view of a circuit board identified in Figure 1; Figure 3 shows the weaving of a wiring loom; Figure 4 details the weaving machine identified in Figure 3; Figure 5 shows a portion of a woven loom; Figure 6 shows a cross section of the loom identified in Figure 5; Figure 7 shows an example of a peripheral device connector; Figure 8 shows a circuit board for supporting a peripheral device connector; Figure 9 shows a peripheral device connector attached to a circuit board; Figure 10 shows a further embodiment of an apparatus for inclusion within an item of clothing; Figure 11 shows individual encapsulated circuit boards; Figure 12 shows the location of an outer cover over a circuit board; Figure 13 shows an example of a completed loom assembly; Figure 14 shows an example of an item of clothing; Figure 15 illustrates the connection of a loom to a control unit: and Figure 16 shows the attachment of a control unit onto an item of clothing.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Figure 1 An apparatus for inclusion within an item of clothing is shown in Figure 1. In this example, five circuit boards are provided, consisting of a first circuit board 101, a second circuit board 102, a third circuit board 103, a fourth circuit board 104 and a fifth circuit board 105. Electrically conducting wires 111 connect the first circuit board 101 to the second circuit board 102. Similarly, electrically conducting wires 112 connect the second circuit board 102 to the third circuit board 103. Further electrically conducting wires 113 connect the third circuit board 103 to the fourth circuit board 104. Similarly, electrically conducting wires 114 connect the fourth circuit board 104 to the fifth circuit board 105. Electrically conducting wires 115 then connect the fifth circuit board 105 to a control unit interface 116.

Each circuit board includes at least one electrically connected component. A first electrically connected component 121 is included on the first circuit board 101. This may take the form of a light emitting device. The second circuit board 102 includes a second light-emitting device 122 along with a third light-emitting device 123. In this example, the fourth circuit board 104 includes a fourth light-emitting device 124, a fifth light-emitting device 125 and a sixth light-emitting device 126. In further embodiments described herein, each group of light-emitting devices includes a total of three light-emitting devices. However, it should be appreciated that other configurations of light emitting device may be provided and a circuit board could include more than three light-emitting devices.

In this example, the fifth circuit board 105 has a seventh light-emitting device 127, an eighth light-emitting device 128 and a ninth light-emitting device 129. In addition to this, a light detector 130 is also included on the circuit board. Thus, these devices effectively become part of the garment and as such must be capable of withstanding washing cycles.

In many applications, it is also necessary to include devices with a higher level of sophistication, such as devices for providing additional power, devices for detecting gas levels, sound levels and other hazardous attributes, devices for generating output signals, in the form of audible alarms for example, and devices for providing radio communication. These devices cannot be retained on the garment during washing cycles and therefore need to be removed. In many environments, devices of this type, along with a control unit, are removed at the end of an operational shift and then reconnected at the start of the next operational shift. This allows devices of this type to be recharged and, where appropriate, allows control units to be reprogrammed.

To allow peripheral devices to be attached and then detached, the garment may be provided with peripheral device connectors. Thus, in this example, the third circuit board 103 includes a peripheral device connector 131. Furthermore, it should also be appreciated that, in other embodiments, more peripheral device connectors may be included.

A protective moulding 131 encases the circuit boards to form a transportable assembly. In an embodiment, circuit boards are encased or encapsulated in a transparent silicone rubber for subsequent cutting prior to garment assembly.

Extended portions of the moulding extend on both sides of each circuit board. Thus, a first extended portion 141 is above the first circuit board with a second extended portion 142 located between the first circuit board 101 and the second circuit board 102. Similarly, a third extended portion 143 is provided between the second circuit board 102 and the third circuit board 103. A fourth extended portion 144 is provided between the third circuit board 103 and the fourth circuit board 104. A fifth extended portion 145 is provided between the fourth circuit board 104 and the fifth circuit board 105. A sixth extended portion 146 is provided below the fifth circuit board 105.

In an embodiment, the internal extended portions 142 to 145 include indications 147 to show where these extended portions should be cut to define individual circuits.

Figure 2 A cross-sectional view of the second circuit board 102 is shown in Figure 2. The circuit board is completely encapsulated by the protective moulding 131. The second light-emitting device 122 and the third light-emitting device 123 are encapsulated but remain visible due to the transparent nature of the protective moulding 131.

An end of conducting wires 111, where it attaches to the second circuit board 102, is also encapsulated, along with the second conductive wires 112 having ends connected to the second circuit board 102. Due to the presence of the third extended portion 143, the edge of the circuit board 102 is also fully encapsulated and remains fully encapsulated after a cutting operation has taken place, given that this cutting operation takes place through the extended portions and does not involve the cutting of the actual circuit board itself. In this way, once installed within a garment, the totality of the loom may be washed with the garment without risk of water ingress and consequential damage to circuit elements. Each circuit board remains fully encapsulated, thereby resisting delamination even during industrial type washing operations.

Figure 3 The electrically conducting wires 111, 112 etc are encapsulated in a woven material, in an embodiment. Furthermore, in an embodiment, the conductive wires are included during a weaving operation. A schematic representation of a weaving machine 301 is shown in Figure 3. The weaving machine 301 receives a first twisted pair 311 formed from a first conductor and a second conductor. In addition, the weaving machine 301 receives a second twisted pair 312, formed from a third conductor and a fourth conductor. Warp threads 313 are received, along with first weft threads 314 and second weft threads 315.

Material from the warp threads 313 and the weft threads 314/315 are woven around the twisted pairs 311/312. In addition, stitching is placed between the first twisted pair and the second twisted pair to form a first conduit for the first twisted pair and a second conduit for the second twisted pair. In this embodiment the receiving, weaving and stitching operations are performed during a single pass weaving operation. The resulting loom 316 is loaded onto a reel 317, thereby allowing continuous production to be performed until source reels need replacement. Loom portions, such as portions 111, 112, 113 etc are then cut from the reel 317 during the construction of the apparatus described with reference to Figure 1.

Thus, the resulting method provides for the construction of an apparatus for inclusion within an item of clothing. At least one electrically connectable component is attached onto each of a plurality of circuit boards. The circuit boards are electrically connected together by the electrically conducting wires contained within the loom portions. The electrically connected circuit boards are then located within a mould and an over moulding of the circuit boards is performed with extended portions on both sides of each circuit board.

Figure 4 An example of a weaving machine 301 is shown in Figure 4. Warp threads 313 are received substantially vertically and manipulated to facilitate the inclusion of weft threads 314. The resulting loom assembly 316 exits the machine vertically and is thereafter retained on reel 317, as described with reference to Figure 3.

Figure 5 A portion of the loom 316 is shown in Figure 5. A first conductor 501 and a second conductor 502 are twisted together to form a first twisted pair 503. In addition, a third conductor 513 and a fourth conductor 514 form a second twisted pair 515.

A woven material 516 surrounds the first twisted pair 503 and a second twisted pair 515. A line of stitching 517 is applied between the first twisted pair 503 and a second twisted pair 515. This ensures that the two twisted pairs are separated and retained within their own respective conduits.

Figure 6 A cross-section of the loom portion 316 is shown in Figure 6. The first twisted pair is held within the first conduit 521, with the second twisted pair being retained within the second conduit 522.

In an embodiment, each conductor, such as the first conductor 501, includes a conducting inner core 603 and a surrounding insulator 604. In an embodiment, the surrounding insulator 604 is formed from a silicone rubber that is capable of being washed at relatively high temperatures, typically above 80° C. The woven material 516 allows a degree of flexibility to facilitate deployment of the loom within an item of clothing. However, it is also resilient, to ensure that the cables contained therein cannot penetrate the outer surface of the loom. Furthermore, it is difficult for the cables to form loops, which could create positions of weakness and failure.

In this embodiment, the woven material is brought together at each end to form a first securing tab 621 and a second securing tab 622. These securing tabs allow the loom to be secured, possibly by stitching, to an item of clothing. One of the securing tabs may be colour-coded to distinguish the two twisted pairs. In this way, a twisted pair for carrying data can be distinguished from a twisted pair for carrying power.

Figure 7 An example of a peripheral device connector 131, of the type described with reference to Figure 1, is shown in Figure 7. The peripheral device connector is configured to provide a mechanically-detachable electric interface for equipment that is supported on an external surface of an item of clothing.

The peripheral device connector 131 includes a rigid component 701 that is configured to extend externally through an orifice defined in an item of clothing. In addition, the peripheral device connector 701 also includes an internal electrical interface portion 702.

Figure 8 The third circuit board 103 is shown in Figure 8, for supporting the peripheral device connector described with reference to Figure 7. The third circuit board 103 includes first contacts 811 that are attachable to the internal electrical interface portion 702 of the peripheral device connector. The first contacts 811 are electrically connected to a first set of loom contacts 821 and a second set of loom contacts 822.

Figure 9 The peripheral device connector 131 is shown extending from the third circuit board 103 in Figure 9. In this embodiment, the peripheral device connector presents a substantially circular surface 901. When located within a garment, the substantially circular surface 901 lies substantially parallel to an outer surface of the garment to present a plurality of concentric electrical contacts 902.

Figure 10 A further embodiment of an apparatus for inclusion within an item of clothing is shown in Figure 10. In this example, four circuit boards are present, presenting a first circuit board 1001, a second circuit board 1002, a third circuit board 1003 and a fourth circuit board 1004. In this embodiment, each circuit board 1001 to 1004 includes three light emitting devices. Thus, on the first circuit board 1001, electrically connected components take the form of a first light emitting device 1011, a second light-emitting device 1012 and a third light-emitting device 1013.

An interface connector takes the form of a control unit plug 1014 connectable into a control unit as illustrated in Figure 15. The first circuit board 1001 is connected to the control unit plug 1014 via a loom portion 1015.

In this example, the fourth circuit board 1004 has been cut, as indicated by arrow 1016, along an extended portion of the moulding; thereby separating the fourth circuit board 1004 from the remaining assembly. Prior to inclusion within the garment, a further cut is made along indications 1017 to separate the third circuit board 1003. In addition, a further cut is made along indications 1018 to separate the second circuit board 1002 from the first circuit board 1001.

In the embodiment of Figure 10, the circuit boards are solid circuit boards and, in an embodiment, circuit boards identified by the commercial designation FR4 may be deployed, possibly having a thickness of one millimetre and may provide a two-layer configuration.

Figure 11 Individual encapsulated circuit board 1004 is shown in Figure 11. Extended portions 1101 and 1102 extend on both sides of the circuit board 1004, thereby ensuring that the circuit board remains fully encapsulated. Furthermore, in addition to providing this higher level of encapsulation, the extended portions, that may also be identified as wings, flanges or flaps, facilitate the attachment of the circuit board within the garment.

During the assembly process, holes are made in the garment to receive the light emitting devices which, in this example, may be identified as a first light-emitting device 1111, a second light-emitting device 1112, and a third light-emitting device 1113. In an embodiment, arrows 1114 are printed onto the circuit board to indicate the way in which connections should be made. Thus, the arrows indicate movement away from the control unit plug 1014 towards the end of the loom, terminating with the fourth circuit board 1004.

During assembly, the extended portions 1101 and 1102 remain in contact with an inner surface of the garment material. An outer cover 1121 is then located on an outer surface of the garment material. The outer cover 1121 includes three orifices comprising a first orifice 1131, a second orifice 1132 and a third orifice 1133. Light emitting devices 1111 to 1113 are received respectively within orifices 1131 to 1133.

Figure 12 Location of the outer cover 1121 over the fourth circuit board 1004 is shown in Figure 12. As shown in Figure 12, each orifice 1131, 1132 and 1133 has received a respective light emitting device 1111 to 1113.

The outer cover 1121 includes a first indication 1201 and a second indication 1202. These indications provide a guide for a machinist, indicating where stitches are required to attach the circuit board. Thus, during this operation, stitches enter the outer cover 1121, penetrate the material of the garment and then enter an aligned extended portion. Thus, stitches applied along the first indication 1201 are received within the first extended portion 1101 and stitches deployed along the second indication 1202 are received within the second extended portion 1102. Thus, in this way, it is possible to secure the circuit board within the garment, while ensuring that penetration does not occur through the circuit board 1004 itself. Thus, in this way, the circuit board remains fully encapsulated and water ingress during a washing cycle is prevented.

Figure 13 An example of a completed loom assembly is illustrated in Figure 13. The extended portions have been cut to define individual assemblies 1301 to 1304. These individual assemblies are now ready to be positioned against an inner surface of an item of clothing, so that respective covers may be arranged on an outer surface of the item of clothing and a sewing operation performed, such that stitches pass through aligned extended portions.

Figure 14 An example of an item of clothing 1401 is shown in Figure 14. The item of clothing is made from a fluorescent material 1402 with additional light reflective strips 1403. In this embodiment, a loom of the type described with reference to Figure 1 is retained under the light reflective strip 1403.

In this example, a loom-connected peripheral device connector 131 is shown, along with loom connected light-emitting devices 1306.

Figure 15 In order to place the garment into an operational state, the interface terminal 116 is inserted into a control unit, thereby connecting the loom assembly to the control unit, such that the loom assembly and the electrical components included therein may receive power and data from an appropriate control unit. Furthermore, after this insertion has been made, the control unit 1501 may be retained within an internal pocket to provide a degree of mechanical protection.

Figure 16 An alternative embodiment is shown in Figure 16, for which it is not necessary to include the interface terminal 116 and the loom portion 115. As an alternative to providing an interface terminal, such as the control unit plug 1014, an alternative control unit 1601 is provided, with a loom connector for attachment to peripheral device connector 131. Connection of this type allows a supervisor to monitor light-emitting indicators 1602, view data displayed on a visual display screen 1603 and obtain immediate access to an activation button 1604.

Claims

CLAIMSThe invention claimed is: I. An apparatus for inclusion within an item of clothing, comprising: a plurality of circuit boards; electrically conducting wires connecting said circuit boards together to form a loom with an interface terminal; and a protective moulding encasing said circuit boards, wherein: each said circuit board includes at least one electrically connected to component; and an extended portion of said moulding extends on both sides of each said circuit board.
2. The apparatus of claim 1, further comprising indications upon said extended portions indicating where each said extended portion should be cut to define individual light emitting assemblies connected together by said wires.
3. The apparatus of claim 2, further comprising an outer cover locatable over an outer surface of the item of clothing to retain an assembly positioned against an inner surface of the item of clothing, wherein said outer cover includes indications for the application of stitching, such that said stitching penetrates the extended portions of the assembly.
4. The apparatus of any of claims Ito 3, wherein said circuit boards are solid circuit boards.
5. The apparatus of any of claims Ito 4, wherein a said at least one electrically connected component comprises a plurality of light emitting devices 6. The apparatus of claim 5, further comprising a light detection device.7. The apparatus of any of claims 1 to 4, wherein said at least one electrically connected component comprises a peripheral device connector.8. A method of constructing an apparatus for inclusion within an item of clothing, comprising the steps of: attaching at least one electrically connectable component on each of a plurality of circuit boards; electrically connecting said circuit boards together by means of electrically conducting wires; locating the electrically connected circuit boards within a mould; and over moulding said circuit boards with extended portions on both sides of each of the circuit boards.9. The method of claim 8, further comprising the step of cutting the extended portions to define individual assemblies.10. The method of claim 9, further comprising the steps of: positioning an assembly against an inner surface of an item of clothing; arranging a cover against an outer surface of said item of clothing; and sewing the assembly and the cover to the item of clothing, such that said stitches pass through an aligned extended portion.11. The method of claim 10, further comprising the step of inserting an interface terminal into a control unit, wherein said interface terminal is attached to electrically conducting wires attached to an end assembly.12. The method of claim 11, further comprising the step of inserting the control unit within a pocket of the item of clothing.13. The method of claim 12, further comprising the step of supplying power and data from said control unit to said electrically connectable component.15. The method of claim 14, wherein said electrically connected component is a light emitting device, wherein said data controls properties of light emitted by said light emitting device.