Conductive Knitted Fabric Article and Method of Making the Same

Abstract

A fabric article ( 100 ) comprising a continuous body of knitted fabric ( 100 ). The continuous body of fabric ( 100 ) comprises: a base component ( 101 ) comprising a plurality of courses of nonconductive yarn and a sensing component ( 107 ) comprising a first conductive region ( 109 ). The first conductive region ( 109 ) comprises at least one course of conductive yarn. The fabric article 100 ) is manufactured using a knitting machine comprising first and second needle beds. One or both of the first and second needle beds are used to knit the base component ( 101 ). The first needle bed is used to knit the first conductive region ( 109 ). A second conductive region ( 111 ) may be knit using the second needle bed. A conductive pathway ( 113 ) connecting the first conductive region ( 109 ) to the second conductive region ( 111 ) may be knit using the first or second needle bed.

1 - 31 . (canceled) 
     
     
         32 . A fabric article comprising a continuous body of weft knitted fabric, the continuous body of fabric comprises: a base component comprising a plurality of courses of non-conductive yarn and a sensing component comprising a plurality of courses of conductive yarn forming a first conductive region, a conductive pathway, and a second conductive region, wherein the first conductive region and the second conductive region are provided on opposing surfaces of the base component and are spaced apart from one another along a course direction of the fabric article, wherein the conductive pathway extends, in the course direction, along one of the surfaces of the base component between the first and second conductive regions, and wherein part of the conductive yarn forming the conductive pathway extends through the base component so as to electrically connect the first conductive region to the second conductive region. 
     
     
         33 . The fabric article as claimed in  claim 32 , wherein the first conductive region is a three-dimensional conductive region that extends away from a surface of the base component. 
     
     
         34 . The fabric article as claimed in  claim 33 , wherein the first conductive region forms a tube extending from the surface of the base component. 
     
     
         35 . The fabric article as claimed in  claim 33 , wherein a filler material is disposed within the first conductive region. 
     
     
         36 . The fabric article as claimed in  claim 35 , wherein the continuous body of fabric comprises the filler material. 
     
     
         37 . The fabric article as claimed in  claim 36 , wherein the filler material comprises an expanding yarn. 
     
     
         38 . The fabric article as claimed in  claim 32 , wherein the second conductive region is a three-dimensional conductive region that extends away from a surface of the base component. 
     
     
         39 . The fabric article as claimed in  claim 32 , wherein the first conductive region is a three-dimensional conductive region that extends away from a first surface of the base component, and the second conductive region is a three-dimensional conductive region that extends away from a second surface of the base component opposing the first surface. 
     
     
         40 . The fabric article as claimed in  claim 32 , wherein the first and second conductive regions are wider than the conductive pathway. 
     
     
         41 . The fabric article as claimed in  claim 32 , further comprising a gripper component provided on the first or second surface of the base component. 
     
     
         42 . The fabric article as claimed in  claim 32 , wherein the sensing component is a unitary knitted structure formed from a single length of conductive yarn. 
     
     
         43 . The fabric article as claimed in  claim 32 , wherein the base component is a double-knit base component. 
     
     
         44 . A method of manufacturing a fabric article, the method comprising forming a continuous body of weft knitted fabric comprising a base component comprising a plurality of courses of non-conductive and a sensing component comprising a plurality of courses of conductive yarn forming a first conductive region, a conductive pathway, and a second conductive region, wherein the first conductive region and the second conductive region are provided on opposing surfaces of the base component and are spaced apart from one another along a course direction of the fabric article, wherein the conductive pathway extends, in the course direction, along one of the surfaces of the base component between the first and second conductive regions, and wherein part of the conductive yarn forming the conductive pathway extends through the base component so as to electrically connect the first conductive region to the second conductive region. 
     
     
         45 . The method as claimed in  claim 44 , wherein the fabric article is manufactured using a knitting machine comprising a first bed of needles and a second bed of needles. 
     
     
         46 . The method as claimed in  claim 45 , wherein forming the continuous body of fabric comprises knitting, using one or both of the first and second beds, non-conductive yarn to form the base component. 
     
     
         47 . The method as claimed in  claim 46 , wherein forming the continuous body of fabric comprises knitting, using both the first and second beds, non-conductive yarn to form the base component. 
     
     
         48 . The method as claimed in any of  claims 45 , wherein forming the continuous body of fabric comprises knitting, using the first bed, conductive yarn to form the first conductive region. 
     
     
         49 . The method as claimed in  claim 48 , wherein knitting the conductive yarn comprises knitting, using the first bed, one or a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component. 
     
     
         50 . The method as claimed in  claim 45 , wherein forming the continuous body of fabric comprises knitting, using the second bed, conductive yarn to form the second conductive region. 
     
     
         51 . The method as claimed in  claim 50 , wherein forming the second conductive region comprises knitting, using the second bed, a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component.