Conductive yarn/sewing thread capable of data/signal transmission having reduced or eliminated crosstalk, and smart fabric, and garment made therefrom

Abstract

A conductive composite yarn capable of signal or data transmission with minimized crosstalk having: a core formed of at least two metallic strands, wherein the at least two strands of electrically conductive metal are configured such that one strand is wrapped around the other strand, wherein: 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; 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; at least one bonding agent applied onto the at least one outer cover; and optionally, a lubricant.

1 . A conductive composite yarn comprising:
 a) a core formed of at least two strands of an electrically conductive metal of 40 or higher gauge, wherein the at least two strands of electrically conductive metal are configured such that one strand is wrapped around the other strand at a wrap rate of from 1 to 50 turns per inch;   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, wherein the inner cover is a natural or synthetic yarn;   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;   d) at least one bonding agent applied onto the at least one outer cover; and   e) optionally, a lubricant.   
     
     
         2 . The conductive composite yarn of  claim 1 , wherein said core comprises two or more strands of an electrically conductive metal of 40 or higher gauge, each individually wrapped by a further strand of electrically conductive metal of 40 or higher gauge at a wrap rate of from 1 to 50 turns per inch. 
     
     
         3 . The conductive composite yarn of  claim 1 , wherein said electrically conductive metal is copper. 
     
     
         4 . The conductive composite yarn of  claim 3 , wherein the at least two copper wire strands are 42 gauge copper wires. 
     
     
         5 . The conductive composite yarn of  claim 4 , wherein the at least two copper wire strands are 44 gauge copper wires. 
     
     
         6 . The conductive composite yarn of  claim 3 , wherein said core comprises two 40 or higher gauge copper wires, each individually wrapped by a further strand of electrically conductive metal of 40 or higher gauge at a wrap rate of from 1 to 50 turns per inch. 
     
     
         7 . The conductive composite yarn of  claim 6 , wherein the two copper wires and the further strands of electrically conductive metal 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. 
     
     
         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 . The conductive composite yarn according to  claim 1 , wherein the one metallic strand wrapped around the other metallic strand is connected to ground during use. 
     
     
         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.