[0001] The invention pertains to multilayer materials for smart functionalities in textile
materials, such as lighting, heating and/or sensing.
[0002] Development of textile materials comprising smart functionalities are being actively
pursued by many companies. However, most of these developments are focused on a single
type of use.
[0003] There is a demand for textile materials prepared in such a way for smart functionalities
connection which can be utilized for different types of use.
[0004] The object of the invention is achieved by the multilayer material of claim 1. Some
advantageous embodiments of the invention are defined by claims 2 to 15.
[0005] The multilayer material for smart functionalities comprising a textile material,
a first electrically conductive pattern, a second electrically conductive pattern
and an electrically insulating and separating material separating the second electrically
conductive pattern from the first electrically conductive pattern enables to electrically
connect devices onto the multilayer material.
[0006] The term for smart functionalities is understood to mean functionalities requiring
an electrically conductive connector grid or connector scrim for power transmission
and/or data transmission.
[0007] Devices may be connected to the first electrically conductive pattern and the second
electrically conductive pattern for electrical power, trigger signals, digital data
transmission, etc. The devices may be connected onto the multilayer material comprising
the first electrically conductive pattern and the second electrically conductive pattern
such that connections can be made after the multilayer material has been manufactured,
using a "plug and play", "pick and place" type of technology, wherein the first electrically
conductive pattern and the second electrically conductive pattern are already present
in the multilayer material, electrical conduction is provided as well as electrical
insulation is maintained.
[0008] The first electrically conductive pattern comprised in the multilayer material may
be comprised in the textile material as warp threads and/or weft threads in a woven
fabric.
[0009] The second electrically conductive pattern comprised in the multilayer material may
be comprised in the textile material as warp threads and/or weft threads in a woven
fabric.
[0010] In an embodiment, the first electrically conductive pattern and the second electrically
conductive pattern comprised in the multilayer material are comprised in the textile
material, to form a connector grid which is integrated in the textile material.
[0011] A connector grid integrated in the textile material may be obtained by weaving conductive
yarns or filaments of the first electrically conductive pattern into the warp of the
woven fabric, and weaving conductive yarns or filaments of the second electrically
conductive pattern into the weft of the woven fabric during the weaving process and
providing a separating material between the conductive yarns or filaments of the first
electrically conductive pattern and the conductive yarns or filaments of the second
electrically conductive pattern at their crossing points in the woven fabric, thereby
providing a connector grid integrated in the textile material as a woven fabric comprising
conductive yarns or filaments in the warp and weft direction of the woven fabric.
[0012] In another embodiment, the first electrically conductive pattern is comprised as
warp threads and/or weft threads in a first woven fabric and the second electrically
conductive pattern is comprised as warp threads and/or weft threads in a second woven
fabric to form a connector grid.
[0013] A connector grid integrated in the textile material may be obtained by weaving conductive
yarns or filaments of the first electrically conductive pattern into the warp and/or
weft of a first woven fabric, and weaving conductive yarns or filaments of the second
electrically conductive pattern into the warp and/or weft of a second woven fabric
during their respective weaving processes and providing a separating material layer
between the first woven fabric comprising conductive yarns or filaments of the first
electrically conductive pattern and the second woven fabric comprising conductive
yarns or filaments of the second electrically conductive pattern, thereby providing
a connector grid in the multilayer material.
[0014] The first electrically conductive pattern may be comprised in the multilayer material
as a group of parallel threads in a connector scrim.
[0015] The second electrically conductive pattern may be comprised in the multilayer material
as a group of parallel threads in a connector scrim.
[0016] A connector scrim is understood to be a structure composed of at least two sets of
parallel threads, wherein the first group of parallel threads is oriented at an angle,
generally at a 90° angle, to the second group of parallel threads. The first group
of parallel threads may be placed on top of and may be connected to the second group
of parallel threads by chemical bonding to form a laid connector scrim. The first
group of parallel threads may also be interwoven with, and optionally connected by
chemical bonding to, the second group of parallel threads to form a woven connector
scrim. A separating material is provided between the conductive yarns or filaments
of the first electrically conductive pattern and the conductive yarns or filaments
of the second electrically conductive pattern at their crossing points in the scrim.
[0017] In an embodiment, the multilayer material may comprise the first electrically conductive
pattern as a first group of parallel threads and the second electrically conductive
pattern as a second group of parallel threads in a connector scrim, wherein the second
group of parallel threads is oriented at an angle, generally at a 90° angle, to the
first group of parallel threads.
[0018] In another embodiment, the multilayer material may comprise the first electrically
conductive pattern as a first group of parallel threads in a first connector scrim
and the second electrically conductive pattern as a second group of parallel threads
in a second connector scrim, wherein the second group of parallel threads is oriented
at an angle, generally at a 90° angle, to the first group of parallel threads.
[0019] A connector scrim integrated in the textile material may be obtained by using a nonwoven
spunbond technology in which endless filaments are laid down onto a conveyor belt
to form a web of filaments, which is consolidated by a bonding process to form a spunbonded
nonwoven and connecting a connector scrim, preferably a laid scrim or a woven scrim,
to the spunbonded nonwoven. The connector scrim may be built-in or embedded into the
nonwoven, for instance by providing the scrim between sublayers of the laid-down filaments
which form the spunbonded nonwoven.
[0020] The nonwoven of endless filaments may be produced by well-known single step and two-step
spunbonding processes. In single step spunbonding processes filaments are extruded
from a spinneret and subsequently laid down on a conveyor belt as a web of filaments
and subsequently bonding the web to form a consolidated nonwoven layer of fibers.
In two-step processes filaments are spun and wound on bobbins, preferably in the form
of multifilament yarns, followed by the step of unwinding the multifilament yarns
and laying the filaments down on a conveyor belt as a web of filaments and bonding
the web to form a consolidated nonwoven of fibers.
[0021] The nonwoven of endless filaments may be composed of thermoplastic filaments for
at least 50 wt.% of the total weight of fibers in the nonwoven of filaments, preferably
for at least 75 wt.%, more preferably for at least 90 wt.%, even preferably for at
least 95 wt.%. Increasing the amount of thermoplastic filaments in the nonwoven of
filaments increases the tensile strength and/or tear resistance and increases the
flexibility of the multilayer material.
[0022] In an embodiment the nonwoven of filaments is composed for 100 wt.% of thermoplastic
filaments of the total weight of filaments in the nonwoven.
[0023] The thermoplastic polymer from which the thermoplastic filaments in the nonwoven
are composed may be any type of thermoplastic polymer capable of withstanding elevated
temperatures in the desired application. The thermoplastic fibers in the nonwoven
layer of fibers may comprise a polyester, such as for example polyethylene terephthalate
(PET) (based either on DMT or PTA), polybutylene terephthalate (PBT), polytrimethylene
terephthalate (PTT), polyethylene naphthalate (PEN) and/or polylactic acid (PLA),
a polyamide, such as for example polyamide-6 (PA6), polyamide-6,6 (PA6,6) and/or polyamide-6,10
(PA6,10), polyphenylenesulfide (PPS), polyethyleneimide (PEI) and/or polyoxymethylene
(POM) and/or any copolymer or any blend thereof.
[0024] The nonwoven may also comprise natural fibers, such as flax, hemp, cotton, wool,
silk, or other fibers of cellulosic or polypeptide bio-origin.
[0025] The thermoplastic filaments may comprise up to 25 wt.%, based on the total weight
of the filaments, of additives, such as for example spinning auxiliaries, fillers,
flame retardant materials, UV inhibitors, crystallization retarders/accelerators,
plasticizers, heat stabilizers, antimicrobial additives, coloring agents such as for
example carbon black or any combination thereof.
[0026] The weight of the nonwoven comprised in the multilayer material may be in the range
of 20 g/m
2 to 250 g/m
2, preferably in the range of 30 g/m
2 to 100 g/m
2, preferably in the range of 50 g/m
2 to 150 g/m
2.
[0027] In an embodiment the nonwoven of filaments, may be composed of a single type of mono-component
filaments, which are bonded by any suitable bonding technique, such as for example
by calendering the web of filaments between two calender rolls, by mechanical needling,
by hydroentanglement, by ultrasonic bonding or by any combination thereof.
[0028] In another embodiment the nonwoven of filaments, may comprise two types of mono-component
filaments, each type of mono-component filaments being composed of a polymer of different
chemical construction having a different melting point. It is preferred that the melting
points of the two different polymers differ by at least 10°C, preferably by at least
20°C. The melting temperature of a thermoplastic polymer is determined by Differential
Scanning Calorimetry (DSC) as the temperature at the maximum value of the endothermic
melting peak upon heating of the polymer at a rate of 20°C/min. Such a product could
be thermally bonded by subjecting the web of filaments to a temperature in the range
of the melting point of the polymer with the lower melting point.
[0029] In yet another embodiment the nonwoven of filaments, may comprise bicomponent filaments.
Bicomponent filaments are filaments composed of two polymers of different chemical
construction. A basic distinction is being drawn between three types of bicomponent
filaments: side-by-side types, core-sheath types and islands-in-the-sea types bicomponent
filaments. In an embodiment the melting points of the two polymers building the bicomponent
fibers differ by at least 10°C, preferably at least 20°C. Such a nonwoven comprising
bicomponent filaments, when composed of side-by-side types and/or core-sheath type
bicomponent fibers, could be thermally bonded by subjecting the web of filaments to
a temperature in the range of the melting point of the polymer with the lower melting
point. In a preferred embodiment the nonwoven is predominantly made from core-sheath
type bicomponent filaments. Predominantly is understood to mean that at least 50%
of the filaments comprised in the nonwoven are core-sheath type bicomponent filaments,
preferably at least 75%, more preferably at least 90%, even more preferably at least
95%, most preferably 100%.
[0030] Preferably the core/sheath ratio in the core/sheath bicomponent filaments lies between
95/5 Vol.% and 5/95 Vol.%. More preferably the core/sheath ratio lies between 50/50
Vol.% and 95/5 Vol.%.
[0031] In an embodiment the sheath of the core/sheath bicomponent filaments consists mainly
of a polyamide, preferably polyamide-6 (PA6), and the core consists mainly of a polyester,
preferably polyethylene terephthalate (PET).
[0032] Alternatively, the connector scrim may be laminated to or otherwise connected to
a nonwoven or a woven fabric.
[0033] The first electrically conductive pattern may be composed of a conductive material
printed in a pattern, preferably as a first group of parallel lines, onto a surface
of the textile material comprised in the multilayer material. Preferably, the first
electrically conductive pattern is composed of a conductive material printed in a
pattern onto a coating layer which has been pre-applied onto the surface of the textile
material comprised in the multilayer material.
[0034] The second electrically conductive pattern may be composed of a conductive material
printed in a pattern, preferably as a second group of parallel lines, onto a surface
of the textile material comprised in the multilayer material. Preferably, the second
electrically conductive pattern is composed of a conductive material printed in a
pattern onto a coating layer which has been pre-applied onto the surface of the textile
material comprised in the multilayer material.
[0035] In an embodiment, the first electrically conductive pattern and the second electrically
conductive pattern are printed onto the same surface of the textile material comprised
in the multilayer material, and a separating material is provided between the printed
conductive material of the first electrically conductive pattern and the printed conductive
material of the second electrically conductive pattern at their crossing points. Preferably,
the multilayer material comprises the first electrically conductive pattern as a first
group of parallel lines of printed conductive material and the second electrically
conductive pattern as a second group of parallel lines of printed conductive material,
wherein the second group of parallel lines is oriented at an angle, generally at a
90° angle, to the first group of parallel lines to form a connector grid.
[0036] In another embodiment, the first electrically conductive pattern is composed of a
conductive material printed in a pattern, preferably as a first group of parallel
lines, onto a first surface of the textile material comprised in the multilayer material,
and the second electrically conductive pattern is composed of a conductive material
printed in a pattern, preferably as a second group of parallel lines, onto a second
surface of the textile material comprised in the multilayer material, wherein the
second electrically conductive pattern is separated from the first electrically conductive
pattern by the textile material. Preferably, the multilayer material comprises the
first electrically conductive pattern as a first group of parallel lines of printed
conductive material and the second electrically conductive pattern as a second group
of parallel lines of printed conductive material, wherein the second group of parallel
lines is oriented at an angle, generally at a 90° angle, to the first group of parallel
lines to form a connector grid.
[0037] In another embodiment, the first electrically conductive pattern is composed of a
conductive material printed in a pattern, preferably as a first group of parallel
lines, onto a surface of the textile material comprised in the multilayer material,
and the second electrically conductive pattern is composed of a conductive material
printed in a pattern, preferably as a second group of parallel lines, onto a surface
of a further textile material comprised in the multilayer material, wherein the second
electrically conductive pattern is separated from the first electrically conductive
pattern by a separating material, which may be the textile material and/or the further
textile material. Preferably, the multilayer material comprises the first electrically
conductive pattern as a first group of parallel lines of printed conductive material
and the second electrically conductive pattern as a second group of parallel lines
of printed conductive material, wherein the second group of parallel lines is oriented
at an angle, generally at a 90° angle, to the first group of parallel lines to form
a connector grid.
[0038] The multilayer material may comprise the first electrically conductive pattern as
warp threads and/or weft threads in a woven fabric, as a group of parallel threads
in a connector scrim or as a conductive material printed in a pattern onto a surface
of a textile material, and may comprise the second electrically conductive pattern
as warp threads and/or weft threads in a woven fabric, as a group of parallel threads
in a connector scrim or as a conductive material printed in a pattern onto a surface
of the textile material in any combination.
[0039] The connector grid or connector scrim comprised in the multilayer material defines
the location of the first electrically conductive pattern and the location of the
second electrically conductive pattern in the multilayer material, enabling to connect
devices exactly onto the connector grid or the connector grid, for example using a
"plug and play", "pick and place" type of technology, for example by a robot.
[0040] Preferably, the distance between the conductive filaments, yarns, threads or printed
lines of the first electrically conductive pattern in the multilayer material is at
most 5 mm, preferably at most 2 mm, in particular when the multilayer material comprises
at least a third electrically conductive pattern and a fourth electrically conductive
pattern separated from the first electrically conductive pattern and the second electrically
conductive pattern to form at least two connector grids or connector scrims, preferably
in a single plane of the multilayer material, and wherein the at least two connector
grids or connector scrims preferably have a length of 50 cm or less in warp direction
and a width of 50 cm or less in weft direction. The fact that the multilayer material
comprises at least two connector grids or connector scrims in a modular nature, each
connector grid or connector scrim having a length of 50 cm or less in warp direction
and a width of 50 cm or less in weft direction is advantageous for use of the multilayer
material in textile architecture, such as for example as a membrane, in external and
internal building application, such as for example walls, ceilings and floors.
[0041] Preferably, the distance between the conductive filaments, yarns, threads or printed
lines of the second electrically conductive pattern in the multilayer material is
at most 2 mm, preferably at most 1 mm, in particular when the multilayer material
comprises at least a third electrically conductive pattern and a fourth electrically
conductive pattern separated from the first electrically conductive pattern and the
second electrically conductive pattern to form at least two connector grids or connector
scrims, preferably in a single plane of the multilayer material, and wherein the at
least two connector grids or connector scrims preferably have a length of 10 cm or
less in warp direction and a width of 10 cm or less in weft direction. The fact that
the multilayer material comprises at least two connector grids or connector scrims
in a modular nature, each connector grid or connector scrim having a length of 10
cm or less in warp direction and a width of 10 cm or less in weft direction is advantageous
for use of the multilayer material in wearables, garments, shoes, medical and healthcare
applications, and mattress and cushioning comfort products.
[0042] The conductive yarns, filaments or threads comprised in warp and/or in weft direction
in the connector grid or connector scrim may be any conductive yarn, filament or thread,
such as for example filaments, yarns or threads composed of a metal, or filaments,
yarns or threads coated with a metal, or filaments, yarns or threads comprising a
high content of carbon fibers and/or carbon black and/or carbon nanotubes, or filaments,
yarns or threads of polyaniline conductive polymers, or filaments, yarns or threads
comprising graphene and/or carbon nanotubes.
[0043] The conductive filaments, yarns, threads or printed lines of the first electrically
conductive pattern and the conductive filaments, yarns, threads or printed lines of
the second electrically conductive pattern in the multilayer material may exhibit
a capability to withstand mechanical deformation, in particular elongation, of the
multilayer material of at least 1%, preferably at least 2%, more preferably at least
5% without interruption of the electrical conductivity of the conductive filaments,
yarns, threads or printed lines of the first electrically conductive pattern and of
the second electrically conductive pattern. The capability to withstand mechanical
deformation may for example be obtained by filaments, yarns, threads comprising crimps
or other deviations from a straight line. The capability to withstand mechanical deformation
may also be obtained by embroidering or knitting the filaments, yarns, threads into
or onto the textile material. The capability to withstand mechanical deformation may
also be obtained by printing the printed lines in a pattern deviating from a straight
line, such as for example a meandering pattern.
[0044] The separating material separating the second electrically conductive pattern from
the first electrically conductive pattern is selected such that the separating material
is non-conductive, i.e. is electrically insulating.
[0045] The separating material separating the second electrically conductive pattern from
the first electrically conductive pattern may be comprised in the multilayer material
only or at least at crossing points of the conductive filaments, yarns, threads or
printed lines of the second electrically conductive pattern and the conductive filaments,
yarns, threads or printed lines of the first electrically conductive pattern. The
separating material is thus comprised in the multilayer material as multiple separate
small amounts of separating material.
[0046] The separating material separating the second electrically conductive pattern from
the first electrically conductive pattern may be comprised in the multilayer material
as a separating material layer interposed between interposed between the first electrically
conductive pattern and the second electrically conductive pattern, more particular
interposed between the conductive filaments, yarns, threads or printed lines of the
second electrically conductive pattern and the conductive filaments, yarns, threads
or printed lines of the first electrically conductive pattern. The separating material
layer is understood to be a continuous material layer, wherein all the separating
material is connected to each other, i.e. the separating material is not present as
multiple small amounts of separating material.
[0047] The separating material layer may be selected from a wide range of materials, as
long as the material layer separates the second electrically conductive pattern from
the first electrically conductive pattern.
[0048] The separating material layer may be a two-dimensional separating material layer,
wherein the term two-dimensional material layer is understood to mean a material layer
having a thickness of at most 2 mm, as determined according to DIN EN ISO 9073-2 (February
1997).
[0049] The two-dimensional separating material layer may be a nonwoven.
[0050] The nonwoven comprised in the carrier may be any type of nonwoven, such as for example
staple fiber nonwovens produced by well-known processes, such as carding processes,
wet-laid processes or air-laid processes or any combination thereof. The nonwoven
may also be a nonwoven composed of filaments produced by well-known spunbonding processes
wherein filaments are extruded from a spinneret and subsequently laid down on a conveyor
belt as a web of filaments and subsequently bonding the web to form a nonwoven layer
of fibers, or by a two-step process wherein filaments are spun and wound on bobbins,
preferably in the form of multifilament yarns, followed by the step of unwinding the
multifilament yarns and laying the filaments down on a conveyor belt as a web of filaments
and bonding the web to form a nonwoven layer of fibers.
[0051] Preferably, the fibers in the nonwoven are filaments in order to provide higher tensile
strength and/or higher tear strength to multilayer material.
[0052] The nonwoven may be composed of thermoplastic fibers for at least 50 wt.% of the
total weight of fibers in the nonwoven layer of fibers, preferably for at least 75
wt.%, more preferably for at least 90 wt.%, even preferably for at least 95 wt.%.
Increasing the amount of thermoplastic fibers in the nonwoven layer of fibers increases
the tensile strength and/or tear resistance and increases the flexibility of multilayer
material.
[0053] In an embodiment the nonwoven is composed for 100 wt.% of thermoplastic fibers of
the total weight of fibers in the nonwoven.
[0054] The two-dimensional separating material layer may be a woven fabric comprising non-conductive,
or insulating, warp and weft yarns or filaments. The insulating yarns or filaments
comprised in warp and/or in weft direction in the connector grid may be any insulating
yarns or filaments, such as for example yarns or filaments of a thermoplastic polymer
or natural yarns or filaments.
[0055] The two-dimensional separating material layer may be provided as a prefabricated
film or foil composed of non-conductive material.
[0056] The two-dimensional separating material layer may also be provided as a coating layer,
an adhesive layer or a lacquer layer applied between the first electrically conductive
pattern and the second electrically conductive pattern.
[0057] The coating layer, adhesive layer or lacquer layer may be applied as a resin layer.
The resin layer may be a thermoset or thermoplastic resin. The resin layer can be
applied as a coating, calandered or knife-coated, flat die thin film coated or laminated
onto the fabric. A thermoplastic resin enables to obtain a flexible multilayer material.
A thermoset resin enables to obtain a stiff multilayer material.
[0058] The resin of the resin layer may be selected to provide durability to the multilayer
material, in particular to improve the UV stability.
[0059] In an embodiment, the multilayer material comprises a woven fabric the first electrically
conductive pattern and/or the second electrically conductive pattern and a coating
applied on a surface of the woven fabric applied in such a way that the coating comprises
openings or apertures, preferably having an apparent diameter of 100 to 500 µm, which
improves the acoustic of the multilayer material.
[0060] The two-dimensional separating material layer may also be provided as a two-dimensional
mat of extruded entangled filaments. The filaments of the two-dimensional mat of extruded
entangled filaments may be extruded as mono-component filaments. The two-dimensional
mat of extruded filaments may be provided by any suitable process. Preferably, the
two-dimensional structured mat of extruded filaments is provided by extruding polymeric
filaments and collecting the extruded filaments onto a two-dimensional flat surface
by allowing the filaments to bend and to come into contact with each other, preferably
in a still molten state. The filaments of the two-dimensional structured mat of extruded
filaments may thereby be thermally bonded to each other at their crossing points.
Bending of the extruded filaments is preferably initiated by collecting the filaments
onto a flat surface, which defines the flat structure of the two-dimensional mat of
extruded filaments. Preferably, the filaments of the two-dimensional mat of extruded
entangled filaments have a diameter in the range of 0.4 mm to 1.5 mm, more preferably
in the range of 0.6 to 1.0 mm.
[0061] The multilayer material comprising a two-dimensional separating material layer will
exhibit flexibility, which is advantageous, for example for clothing applications.
[0062] The separating material layer may also be a three-dimensional separating material
layer, wherein the term three-dimensional material layer is understood to mean a material
layer having a thickness of at least 2 mm, preferably at least 3 mm, as determined
according to DIN EN ISO 9073-2 (February 1997).
[0063] The three-dimensional separating material layer may provide resilience and comfort
to the multilayer material, which is advantageous, for example for cushioning materials
such as mattresses, seat cushions, wall paddings and automotive interior linings.
[0064] The three-dimensional separating material layer may be a three-dimensional spacer
material, such as a warp-knitted or three-dimensional woven material.
[0065] The three-dimensional separating material layer may be a high loft nonwoven having
a thickness of at least 2 mm, preferably at least 3 mm, which may provide resilience
to the multilayer material. The high loft nonwoven may be a vertically lapped nonwoven.
[0066] The three-dimensional separating material layer may be three-dimensional entangled
mat of extruded filaments. Preferably, the filaments of the three-dimensional structured
mat of extruded filaments are extruded polymeric filaments. The three-dimensional
structured mat of extruded filaments may be provided by any suitable process. Preferably,
the three-dimensional structured mat of extruded filaments is provided by extruding
polymeric filaments and collecting the extruded filaments into a three-dimensional
structure by allowing the filaments to bend and to come into contact with each other,
preferably in a still molten state. The filaments of the three-dimensional structured
mat of extruded filaments may thereby be thermally bonded to each other at their crossing
points. Bending of the extruded filaments is preferably initiated by collecting the
filaments onto a profiled surface, which defines the structure of the three-dimensional
structured mat of extruded filaments. Preferably, the surface on which the filaments
are collected is profiled such that the three-dimensional structured mat of filaments
is shaped into a three-dimensional form which comprises hills and valleys, hemispheres,
positive and/or negative cuspates, cups and/or waffles, pyramids, U-grooves, V-grooves,
cones and/or cylinders capped with a hemisphere.
[0067] The three-dimensional separating material layer may be a thermoplastic honeycomb
structure.
[0068] The honeycomb structure may be produced by any suitable process. For example,
WO 2006/053407 A1 discloses a folded honeycomb structure which is produced from an uncut continuous
web of material by plastic deformation perpendicular to the plane of the material
to thereby form half-hexagonal cell walls and small connecting areas. By folding the
plastically deformed material in the direction of conveyance the half-hexagonal cell
walls meet to form the honeycomb structure.
[0069] The three-dimensional separating material layer may be a double woven structure.
Preferably, the double woven structure comprises associated double layers in some
sections in the warp direction and/or weft direction, the woven structure plies that
form the associated double layers being woven together at least at two or at three
of their longitudinal edges and/or end edges, and comprising threads extending perpendicularly
to the warp direction and to the weft direction which hold together the plies that
from the associated double layers as disclosed in
WO2019011482 A1.
[0070] The three-dimensional separating material layer may be a warp-knitted fabric.
[0071] A three-dimensional separating material layer enables to obtain a multilayer material
having higher stiffness, in particular when the three-dimensional separating material
layer is impregnated with a resin, especially with a thermoset resin, which enables
piezo-electric energy harvesting, for example when the multilayer material is applied
in dance floors, under roads or as railway sleepers.
[0072] The first electrically conductive pattern and a second electrically conductive pattern
separated from the first electrically conductive pattern by a separating material
forming a connector grid or connector grid comprise electrically conductive yarns,
filaments, threads or lines enabling to connect devices onto the connector grid or
connector grid for lighting purposes, such as light emitting diodes (LED's), capacitive
devices for sensing purposes, low-conductive devices for heating purposes, or actuators
and other systems reacting on an external stimulus and providing the desired functionality.
[0073] The devices may be connected to the connector grid or connector scrim for electrical
power, trigger signals, digital data transmission, etc. The devices may be connected
onto the multilayer material comprising the connector grid or connector scrim such,
that connections can be made after the multilayer material has been manufactured,
using a "plug and play", "pick and place" type of technology, wherein the connector
grid or connector scrim is already present in the multilayer material, electrical
(signal, power) conduction is provided as well as electrical insulation is maintained.
[0074] The multilayer material may comprise one or more additional material layers comprising
one or more further electrically conductive patterns separated by separating material
to enable connection of multiple devices having different smart functional ities.
[0075] The multilayer material may comprise at least a third electrically conductive pattern
and a fourth electrically conductive pattern separated from the first electrically
conductive pattern and the second electrically conductive pattern to form more than
one connector grid or connector scrim enabling to provide a modular system for smart
functionalities. Preferably, the multilayer material comprises at least two connector
grids and/or connector scrims spaced apart from each other in a single plane of the
multilayer material.
[0076] The dimensions of the at least two connector grids and/or connector scrims may be
varied widely to support the desired application.
[0077] In an embodiment the at least two connector grids connector scrims comprised in the
multilayer material may a length of 50 cm or less in warp direction and a width of
50 cm or less in weft direction, to enable that the multilayer material can be cut
into desired dimensions, for example for application in carpet tiles, tents or mattresses.
[0078] In another embodiment, the at least two connector grids and/or connector scrims comprised
in the multilayer material may a length 10 cm or less in warp direction and a width
of 10 cm or less in weft direction, to enable that the multilayer material can be
cut into desired dimensions, for example for application in clothing.
[0079] The electronic devices which can be connected to the connector grid or connector
scrim comprised in the multilayer material may subsequently be attached to the connector
grid or connector scrim. This attachment may involve a "pick and place" type of technology
and is aimed at ensuring that the resulting "smart" multilayer material or fabric
is ready for use in its final application. Ready for use means that the said devices
are connected to the connector (power) grid in such a way that their function is secured,
e.g. lighting, heating, sensing or actuating.
[0080] A multilayer material in which the connector grid or connector scrim is comprised
or embedded in the afore described way, i.e. preferably with a coating or embedding
resin, may also be referred to as an "enabling smart (coated) fabric".
[0081] This enabling smart (coated) fabric can be made in such a way that the final desired
"smart" functionality such as described above is not yet determined or added in the
pattern or sequence it is meant to have in the final application. It is therefore
fit as a "scaffold" coated smart fabric for multiple use and moreover a fabric from
which the smart functional device can be removed in such a way as to render the fabric
re-usable. It therefore allows a high degree of freedom of design and cost efficiency,
rendering it as an attractive base coated fabric in applications such as, but not
limited to, textile architecture, both for interior and façade exterior building,
tenting and (solar) shading, automotive and transportation covers or tarpaulins, etc.
In particular, for external applications, the fabric could be made in such a way that
energy harvesting devices, such as (flexible) photovoltaic devices, could be integrated
into, or laminated on, the enabling smart coated fabric providing the additional advantage
of rendering the resulting smart textile independent of an existing power grid and
providing its own energy harvesting function which, combined with a convenient (flexible)
power storage device, allowing to have a light-weight, flexible, transportable, powergrid-independent,
smart functional coated fabric for said applications.
1. A multilayer material for smart functionalities comprising a textile material, a first
electrically conductive pattern, a second electrically conductive pattern wherein
the second electrically conductive pattern is separated from the first electrically
conductive pattern by an electrically insulating and separating material.
2. The multilayer material according to claim 1 wherein the first electrically conductive
pattern is comprised as warp threads and/or weft threads in a woven fabric.
3. The multilayer material according to claim 1 wherein the second electrically conductive
pattern is comprised as warp threads and/or weft threads in a woven fabric.
4. The multilayer material according to any of claims 2 to 3 wherein the first electrically
conductive pattern is comprised as warp threads in the woven fabric and the second
electrically conductive pattern is comprised as weft threads in the woven fabric.
5. The multilayer material according to claim 1 wherein the first electrically conductive
pattern is comprised as a first group of parallel threads and the second electrically
conductive pattern is comprised as a second group of parallel threads in a connector
scrim, wherein the second group of parallel threads is oriented at an angle, generally
at a 90° angle, to the first group of parallel threads.
6. The multilayer material according to claim 1 wherein the first electrically conductive
pattern and/or the second electrically conductive pattern is printed onto the textile
material or onto a coating layer which has been pre-applied onto the surface of the
textile material.
7. The multilayer material according to any of the previous claims 1 wherein the separating
material is applied at least at crossing points of the first electrically conductive
pattern and/or the second electrically conductive pattern.
8. The multilayer material according to any of claims 1 to 6 wherein the separating material
is a separating material layer interposed between the first electrically conductive
pattern and the second electrically conductive pattern.
9. The multilayer material according to claim 8 wherein the separating material layer
is a two-dimensional separating material layer, preferably selected from the group
consisting of a foil, a film, a nonwoven, a woven fabric, a coating layer, an adhesive
layer, a lacquer layer, and a two-dimensional mat of extruded entangled filaments.
10. The multilayer material according to claim 8 wherein the separating material layer
is a three-dimensional material layer, preferably selected from the group consisting
of a three-dimensional spacer material, a warp-knitted fabric, a double woven fabric,
a high loft nonwoven fabric, a vertically lapped nonwoven, a three-dimensional entangled
mat of extruded filaments, a thermoplastic honeycomb structure.
11. The multilayer material according to claim 1 wherein the first electrically conductive
pattern and/or the second electrically conductive pattern is integrated in the textile
material.
12. The multilayer material according to any of the previous claims wherein the conductive
filaments, yarns, threads or printed lines of the first electrically conductive pattern
and the conductive filaments, yarns, threads or printed lines of the second electrically
conductive pattern deviations from a straight line comprise deviations from a straight
line..
13. The multilayer material according to any of the preceding claims wherein the multilayer
material comprises at least a third electrically conductive pattern and a fourth electrically
conductive pattern separated from the first electrically conductive pattern and the
second electrically conductive pattern to form at least two connector grids or connector
scrims.
14. The multilayer material according to claim 13 wherein the at least two connector grids
or connector scrims have a length of 50 cm or less in warp direction and a width of
50 cm or less in weft direction, in particular for textile architecture applications
or building applications, or a length of 10 cm or less in warp direction and a width
of 10 cm or less in weft direction, in particular for wearables, garments, shoes,
medical and healthcare applications, and mattress and cushioning comfort products.
15. A system having smart functionality comprising the multilayer material according to
any of the preceding claims and one or more devices connected onto the connector grids
and/or connector scrims.