Conductive yarn/sewing thread capable of data/signal transmission having an exterior conductive wire, and smart fabric, and garment made therefrom

Abstract

A conductive composite yarn/sewing thread comprising: a) a core formed of at least a first strand of a conductive metal of 40 or higher gauge, and b) at least one inner cover wrapped around the core in a first direction at a rate sufficient to provide substantially complete coverage of the core by the inner cover; c) at least one outer cover wrapped around the at least one inner cover, wherein the outer cover is wrapped in a second direction opposite to a direction of a cover layer on which the outer cover is directly wrapped, at a rate sufficient to provide substantially complete cover of the cover layer on which the outer cover is directly wrapped; wherein one of the inner cover or the outer cover contains a second strand of conductive metal of 40 or higher gauge, and is configured such that a distance between said second strand and said at least first strand is substantially constant; and d) optionally, a lubricant, and a stretch conductive composite yarn, comprising: a core formed from an elastic yarn, and at least one cover layer wrapped helically around the core, wherein the at least one cover layer comprises a natural or synthetic yarn having contained therein a bare conductive metallic strand of 40 or higher gauge; a conductive composite sewing thread therefrom, and use of the yarn/sewing thread in production of a variety of items, including, but not limited to, smart fabrics or smart garments having electrical segments, patterns, or grids therein

1 . A conductive composite yarn/sewing thread comprising:
 a) a core formed of at least a first strand of a conductive metal of 40 or higher gauge, and   b) at least one inner cover wrapped around the core in a first direction at a rate sufficient to provide substantially complete coverage of the core by the inner cover;   c) at least one outer cover wrapped around the at least one inner cover, wherein the outer cover is wrapped in a second direction opposite to a direction of a cover layer on which the outer cover is directly wrapped, at a rate sufficient to provide substantially complete cover of the cover layer on which the outer cover is directly wrapped; wherein one of the inner cover or the outer cover contains a second strand of bare conductive metal of 40 or higher gauge, and is configured such that a distance between said second strand and said at least first strand is substantially constant; and   d) optionally, a lubricant.   
     
     
         2 . The conductive composite yarn of  claim 1 , wherein said at least first strand comprises two or more strands of an electrically conductive metal of 40 or higher gauge, wherein all but one of the two or more strands is coated with an insulating cover or polymer. 
     
     
         3 . The conductive composite yarn of  claim 1 , wherein said electrically conductive metal of said at least first strand, said second strand, or both, is copper. 
     
     
         4 . The conductive composite yarn of  claim 3 , wherein said at least first strand, said second strand, or both, are 42 gauge copper wires. 
     
     
         5 . The conductive composite yarn of  claim 3 , wherein said at least first strand, said second strand, or both, are 44 gauge copper wires. 
     
     
         6 . The conductive composite yarn of  claim 3 , wherein said core comprises two 40 or higher gauge copper wires, wherein one of the two strands is coated with an insulating cover or polymer. 
     
     
         7 . The conductive composite yarn of  claim 6 , wherein the two copper wires are each of 44 gauge. 
     
     
         8 . The conductive composite yarn of  claim 7 , wherein said core further comprises a stainless steel wire having a diameter of 1-2 mil, which is also coated with an insulating cover or polymer. 
     
     
         9 . The conductive composite yarn of  claim 1 , wherein said outer cover is formed of at least one strand of a yarn selected from the group consisting of nylon and polyester yarns. 
     
     
         10 . The conductive composite yarn according to  claim 1 , wherein said core further comprises fiberglass having a denier of from 100 to 300. 
     
     
         11 . The conductive composite yarn according to  claim 1 , wherein the conductive composite yarn is a conductive composite sewing thread. 
     
     
         12 . The conductive composite yarn according to  claim 1 , wherein the yarn has a composite denier of from 400 to 700. 
     
     
         13 . The conductive composite yarn according to  claim 1 , wherein the yarn has a composite denier of from 500 to 600. 
     
     
         14 . The conductive composite yarn according to  claim 1 , wherein the lubricant is a composition comprising silicone and paraffin. 
     
     
         15 . A stretch conductive composite yarn, comprising:
 a core formed from an elastic yarn, and   at least one cover layer wrapped helically around the core, wherein the at least one cover layer comprises a natural or synthetic yarn having contained therein a bare conductive metallic strand of 40 or higher gauge.   
     
     
         16 . A fabric having a conductive segment, pattern or grid, comprising:
 a knit or woven fabric, and   a segment, pattern or grid formed on the fabric by sewing the conductive composite yarn of  claim 1  into the fabric to form the segment, pattern or grid.   
     
     
         17 . A garment having a conductive segment, pattern or grid, formed from the fabric of  claim 16 . 
     
     
         18 . The garment of  claim 17 , further comprising one or more sensors capable of transmitting data signals through the conductive composite yarn, wherein the one or more sensors are electrically connected to one or more ends of the conductive composite yarn. 
     
     
         19 . A garment having a conductive segment, pattern or grid, comprising:
 a garment comprising a fabric, and   a segment, pattern or grid formed on the garment by sewing the conductive composite yarn of  claim 1  into the fabric to form the segment, pattern or grid.   
     
     
         20 . The garment of  claim 19 , further comprising one or more sensors capable of transmitting data signals through the conductive composite yarn, wherein the one or more sensors are electrically connected to one or more ends of the conductive composite yarn. 
     
     
         21 . A fabric having a conductive segment, pattern or grid, comprising:
 a knit or woven fabric, and   a segment, pattern or grid formed on the fabric by sewing the conductive composite yarn of  claim 15  into the fabric to form the segment, pattern or grid.   
     
     
         22 . A garment having a conductive segment, pattern or grid, formed from the fabric of  claim 21 . 
     
     
         23 . The garment of  claim 22 , further comprising one or more sensors capable of transmitting data signals through the conductive composite yarn, wherein the one or more sensors are electrically connected to one or more ends of the conductive composite yarn. 
     
     
         24 . A garment having a conductive segment, pattern or grid, comprising:
 a garment comprising a fabric, and   a segment, pattern or grid formed on the garment by sewing the conductive composite yarn of  claim 15  into the fabric to form the segment, pattern or grid.   
     
     
         25 . The garment of  claim 24 , further comprising one or more sensors capable of transmitting data signals through the conductive composite yarn, wherein the one or more sensors are electrically connected to one or more ends of the conductive composite yarn.