Electrocoated conductive fabric

Abstract

The present invention generally relates to an insulated electrically conductive textile comprising a textile selected from the group consisting of nonwoven, woven, and knit comprising nonconductive fibers or yarns and at least 1 elongated conductive element and either another elongated conductive element or another conductive body. The conductive bodies cross at a point to form an electrical junction that is covered with an insulating coating. The insulating coating is substantially located only on the conductive bodies and is substantially continuous along the outer perimeter of the elongated conductive elements.

1 . An insulated electrically conductive textile comprising a textile selected from the group consisting of nonwoven, woven, and knit comprising nonconductive fibers or yarns and at least 2 conductive bodies having an electrically insulating coating that cross at a point to form an electrical junction, wherein the electrically insulating coating is substantially located only on the conductive bodies, wherein the electrically insulating coating covers at least 50% of the surface area of the conductive bodies and greater than 99% of the surface area of the electrical junction, and wherein the insulating coating on the conductive bodies and the electrical junction are formed of the same materials. 
     
     
         2 . The insulated electrically conductive textile of  claim 1 , wherein the conductive bodies comprise at least 2 elongated conductive elements. 
     
     
         3 . The insulated electrically conductive textile of  claim 1 , wherein the conductive bodies comprise at least 1 elongated conductive element and at least one electrically conductive connector. 
     
     
         4 . The insulated electrically conductive textile of  claim 1 , wherein the insulating coating is formed on the conductive bodies and the electrical junction simultaneously. 
     
     
         5 . The insulated electrically conductive textile of  claim 1 , wherein the conductive bodies comprise a metal selected from the group consisting of stainless steel, nickel, aluminum, copper, tin, silver, gold, and alloys thereof. 
     
     
         6 . The insulated electrically conductive textile of  claim 1 , wherein the conductive bodies comprise carbon. 
     
     
         7 . The insulated electrically conductive textile of  claim 1 , wherein the electrically insulating coating comprises a polymeric material. 
     
     
         8 . The insulated electrically conductive textile of  claim 1 , wherein the conductive textile is flexible. 
     
     
         9 . The insulated electrically conductive textile of  claim 1 , wherein the electrically insulating coating covers at least 95% of the surface area of the conductive bodies. 
     
     
         10 . The insulated electrically conductive textile of  claim 2 , wherein the electrically insulating coating is continuous between the elongated conductive elements. 
     
     
         11 . The insulated electrically conductive textile of  claim 3 , wherein the electrically insulating coating is continuous between the electrically conductive connector and the elongated conductive element. 
     
     
         12 . The insulated electrically conductive textile of  claim 1 , wherein the nonconductive fibers comprise less than 10% by weight insulating coating. 
     
     
         13 . A process for producing an insulated electrically conductive textile comprising:
 providing an solution comprising an ionizable moiety;   depositing a conductive textile selected from the group consisting of nonwoven, woven, and knit comprising nonconductive fibers or yarns and at least two conductive bodies forming an electrical junction and a conductive electrode in contact with the solution;   applying an electric potential between the conductive textile and the conductive electrode, causing the ionizable moieties to deposit selectively on the elongated conductive bodies of the textile forming an electrically insulating coating substantially only on the conductive bodies, wherein the electrically insulating coating covers at least 50% of the surface area of the conductive bodies and greater than 99% of the surface area of the electrical junction;   removing the insulated conductive textile from the solution;   rinsing the insulated conductive textile; and   curing the insulated conductive textile.   
     
     
         14 . The insulated electrically conductive textile of  claim 13 , wherein the conductive bodies comprise at least 2 elongated conductive elements. 
     
     
         15 . The insulated electrically conductive textile of  claim 13 , wherein the conductive bodies comprise at least 1 elongated conductive element and at least one electrically conductive connector. 
     
     
         16 . The process of  claim 13 , further comprising cleaning and rinsing the conductive textile before depositing the conductive textile into the aqueous solution. 
     
     
         17 . The process of  claim 13 , further comprising pretreating with an acid bath and rinsing the conductive textile before depositing the conductive textile into the aqueous solution. 
     
     
         18 . The process of  claim 13 , wherein the conductive electrode comprises graphite. 
     
     
         19 . The process of  claim 13 , wherein the conductive textile serves as the anode. 
     
     
         20 . The process of  claim 14 , wherein the electrically insulating coating is substantially continuous along the outer perimeter of the elongated conductive elements. 
     
     
         21 . The process of  claim 13 , wherein the nonconductive fibers comprise less than 10% by weight insulating coating after the textile is cured. 
     
     
         22 . The insulated electrically conductive textile of  claim 14 , wherein the electrically insulating coating is continuous between the elongated conductive elements.