Electrical Components Attached to Fabric

Abstract

An item may include fabric having insulating and conductive yarns or other strands of material. The conductive strands may form signal paths. Electrical components can be mounted to the fabric. Each electrical component may have an electrical device such as a semiconductor die that is mounted on an interposer substrate. The interposer may have contacts that are soldered to the conductive strands. A protective cover may encapsulate portions of the electrical component. To create a robust connection between the electrical component and the fabric, the conductive strands may be threaded through recesses in the electrical component. The recesses may be formed in the interposer or may be formed in a protective cover on the interposer. Conductive material in the recess may be used to electrically and/or mechanically connect the conductive strand to a bond pad in the recess. Thermoplastic material may be used to seal the solder joint.

What is claimed is: 
     
         1 . A method for attaching an electrical component to fabric having a conductive strand, wherein the electrical component has a trench and a contact pad in the trench, the method comprising:
 depositing solder in the trench;   inserting a conductive strand into the trench;   inserting thermoplastic material into the trench; and   applying heat to reflow the solder and melt the thermoplastic material in the trench.   
     
     
         2 . The method defined in  claim 1  wherein the electrical component comprises a protective cover and wherein the trench is formed in the protective cover. 
     
     
         3 . The method defined in  claim 2  wherein the protective cover comprises thermoplastic. 
     
     
         4 . The method defined in  claim 1  wherein applying heat comprises inductively applying heat with an induction coil. 
     
     
         5 . The method defined in  claim 4  further comprising:
 with a transducer, applying force to press the fabric and the electrical component together to guide the conductive strand into the trench. 
 
     
     
         6 . The method defined in  claim 1  wherein the thermoplastic material comprises a protrusion and wherein inserting the thermoplastic material into the trench comprises inserting the protrusion into the trench. 
     
     
         7 . The method defined in  claim 1  further comprising:
 inserting the electrical component into a pocket in the fabric. 
 
     
     
         8 . The method defined in  claim 1  wherein the thermoplastic material has an opening and wherein inserting the conductive strand into the trench comprises inserting the conductive strand through the opening and into the trench. 
     
     
         9 . The method defined in  claim 8  wherein applying heat comprises applying heat to close the opening in the thermoplastic material such that the conductive strand is enclosed within the trench. 
     
     
         10 . A method for attaching an electrical component to fabric having a conductive strand, wherein the electrical component has a trench and a contact pad in the trench, the method comprising:
 depositing solder into the trench;   inserting thermoplastic into the trench;   inserting the conductive strand into an opening in the thermoplastic material and into the trench; and   applying heat to reflow the solder and melt the thermoplastic material in the trench.   
     
     
         11 . The method defined in  claim 10  wherein the electrical component has a protective structure and wherein the trench is located in the protective structure. 
     
     
         12 . The method defined in  claim 10  wherein applying heat comprises applying heat to close the opening in the thermoplastic material such that the conductive strand is enclosed within the trench. 
     
     
         13 . The method defined in  claim 10  wherein the protective structure comprises thermoplastic. 
     
     
         14 . The method defined in  claim 10  wherein applying heat comprises applying heat through induction. 
     
     
         15 . A method for attaching an electrical component to fabric during formation of the fabric, wherein the fabric has a conductive strand and the electrical component has a contact pad and a protective structure with a trench that exposes the contact pad, the method comprising:
 depositing solder into the trench;   inserting the conductive strand into the trench; and   applying heat to reflow the solder and electrically connect the conductive strand to the contact pad in the trench.   
     
     
         16 . The method defined in  claim 15  further comprising:
 inserting the electrical component into a pocket in the fabric. 
 
     
     
         17 . The method defined in  claim 16  further comprising:
 inserting thermoplastic material into the trench, wherein applying heat comprises applying heat to melt the thermoplastic material in the trench. 
 
     
     
         18 . The method defined in  claim 17  wherein the solder forms a solder connection between the conductive strand and the contact pad and wherein the thermoplastic material seals the solder connection. 
     
     
         19 . The method defined in  claim 17  further comprising:
 forming an opening in the thermoplastic material, wherein inserting the conductive strand into the trench comprises inserting the conductive strand through the opening and into the trench. 
 
     
     
         20 . The method defined in  claim 19  wherein applying heat comprises applying heat to close the opening in the thermoplastic material such that the conductive strand is enclosed within the trench.