Method and apparatus to create electrical junctions for information routing in textile structures

Abstract

Disclosed are systems or apparatuses and methods for forming a junction between conductive fibers that are incorporated into a fabric. Briefly, one method includes the steps of removing insulation from two intersecting individually insulated conductive fibers to expose the individually conductive fibers, bringing the exposed individually conductive fibers into contact with each other at a junction point, and forming a molecular bond between the conductive fibers at the junction point. Also disclosed are systems for forming a junction between conductive fibers that are incorporated into a fabric. In this regard, one embodiment of such a system can include a first apparatus that removes insulation from two intersecting individually insulated conductive fibers to expose the individually conductive fibers, a second apparatus that brings the exposed individually conductive fibers into contact with each other at a junction point, and a third apparatus that aids in formation of a molecular bond between the conductive fibers at the junction point.

1 - 35 . (canceled) 
     
     
         36 . A system that forms a junction between individually electrical conductive fibers or sections of an individually electrical conductive fiber incorporated into a woven fabric, comprising:
 a loom, the loom having harnesses configured to receive and provide fibers in warp and filling directions in the loom and to produce a woven fabric thereby, the fibers including non-conductive fibers and at least one individually conductive fiber, the harnesses configured to form a warp/filling intersection within the woven fabric including non-conductive fibers of sections of the individually electrical conductive fiber or at least two individually conductive fibers,   the loom including a beater roll and a take up roll and an apparatus positioned between the beater roll and the take up roll, the apparatus configured to bring the at least two of the individually electrical conductive fibers or the at least two sections of the individually electrical conductive fiber into contact with each other at the warp/filling intersection within the woven and configured to form a an electrical conductive bond between the at least two of the individually electrical conductive fibers or the at least two of the sections of the individually electrical conductive fiber at the warp/filling intersection, thereby forming the junction between the at least two of the individually electrical conductive fibers or the at least two sections of the individually electrical conductive fiber,   the apparatus having components disposed on opposite sides of the woven fabric designed to bring the at least two of the individually electrical conductive fibers or the at least two sections of the individually electrical conductive fiber into contact with each other at the warp/filling intersection,   means positioned on the loom after the beater roll and before the take up roll for moving at least one of said components across the woven fabric to the warp/filling intersection and for forming the conductive bond at the warp/filling intersection, said means designed to move in at least two of the X, Y and Z directions along the woven fabric and towards and away from the woven fabric, and   means for forming the conductive bond at the warp/filling intersection causing the junction to be formed at the warp/filling intersection within the woven fabric.   
     
     
         37 . A system that forms junctions between individually electrical conductive fibers or sections of an individually electrical conductive fiber incorporated into a woven fabric, comprising:
 a loom, the loom having harnesses configured to receive and provide fibers in warp and filling directions in the loom and to produce a woven fabric thereby, the fibers including non-conductive fibers and at least one individually conductive fiber, the harnesses configured to form a plurality of warp/filling intersections within the woven fabric including non-conductive fibers of sections of the individually electrical conductive fiber or at least two individually conductive fibers,   the loom including a beater roll and a take up roll and an apparatus positioned between the beater roll and the take up roll, the apparatus configured to bring at least two of the individually electrical conductive fibers or at least two sections of the individually electrical conductive fiber into contact with each other at a selected plurality of the warp/filling intersections within the woven fabric and configured to form a an electrically conductive bond between the at least two of the individually electrical conductive fibers or the at least two sections of the individually electrical conductive fiber at each of the selected warp/filling intersections, thereby forming the junctions between the individually electrical conductive fibers or the sections of the individually electrical conductive fiber,   wherein the loom is designed to continuously produce the woven fabric including the junctions within the woven fabric, and wherein the device further comprises at least one of:   a rail upon which the apparatus is situated, the apparatus configured for movement in at least two of the X, Y, and Z directions along the woven fabric and towards and away from the woven fabric, the rail being disposed to one side of the woven fabric, or a turntable to which the first apparatus is connected.   
     
     
         38 . The system of  claim 36 , wherein the apparatus includes an ultrasonic welder. 
     
     
         39 . The system of  claim 36 , wherein the conductive bond includes a conductive fiber and a connector. 
     
     
         40 . The system of  claim 36 , wherein the individually conductive fibers or sections of the individually conductive fiber are insulated and the system further comprises:
 means for removing insulation from the conductive fibers or sections of an individually conductive fiber at the warp/filling intersection; and   means for depositing a conductive material at the warp/filling intersection.   
     
     
         41 . The system of  claim 40 , wherein the conductive material comprises a conductive paste that ensures that bonding occurs between the conductive fibers or sections at the warp/filling intersection and increases conductivity between the conductive fibers or sections at the warp/filling intersection. 
     
     
         42 . The system of  claim 40 , wherein the means for removing the insulation is selected from the group consisting of a solvent dispenser, a chemical etching apparatus, an ultrasonic welder, a laser, and a heating apparatus. 
     
     
         43 . The system of  claim 36 , wherein the apparatus that brings the at least two fibers or sections into contact with each other at the junction point comprises an ultrasonic welder. 
     
     
         44 . The system of  claim 36 , wherein the apparatus comprises:
 means for exciting the conductors;   means for breaking atomic bonds within each individual conductor; and   means for triggering atomic binding forces between the two conductors.   
     
     
         45 . The system of  claim 36 , further comprising means to identify a desired location within the woven fabric and between the beater roll and take up roll for the warp/filling intersection. 
     
     
         46 . The system of  claim 36 , wherein the individually conductive fibers or sections of the individually conductive fiber are insulated, and the system further comprises means for selectively removing insulation at the warp/filling intersection. 
     
     
         47 . The system of  claim 40 , wherein the apparatus includes a first component disposed on opposite sides of the woven fabric configured to bring the at least two of the individually electrical conductive fibers or the at least the sections of the individually conductive fiber into contact with each other, and a second component configured to form the conductive bond, the second component selected from the group consisting of a chemical deposition device, a laser, an ultrasonic welder, and a heating apparatus. 
     
     
         48 . The system of  claim 40 , wherein the apparatus that brings the at least two fibers or sections into contact with each other at the intersection is an ultrasonic welder.