Propel, LLC

Anjali Khemani

Clare King

Birgit Leitner

A machine knittable hybrid yarn is disclosed. The hybrid yarn includes one or more electrically non-conductive yarns and two or more electrically conductive wires wrapped around the electrically non-conductive yarns. The electrically conductive wires have an exterior layer of an insulated material. The electrically non-conductive yarns include a majority fraction of an overall cross-section of the hybrid yarn. The two or more electrically conductive wires are wrapped around the one or more electrically non-conductive yarns at between 1 and 15 twists per inch. The one or more electrically non-conductive yarns are 1500 denier or finer.

Machine-knittable conductive hybrid yarns

A system for continuously humidifying a textile electrode during its use by a human is disclosed. The electrode can be part of a garment or textile where the textile electrode is positioned against the skin. A reservoir positioned against the electrode and opposite the user's skin can be made from a material with hydrophilic and hydrophobic properties, such as natural wool or a skincore material. The reservoir receives and retains moisture from the user's skin through the electrode, as well as from a pre-wetting of the exposed user-facing side of the electrode. A seal can surround the reservoir and the electrode, with the seal extending beyond electrode. The seal can be a patch with heat activated adhesive at the edge to flow the textile to form a moisture barrier around the electrode. An electrical contact on the electrode can connect conductive wires from outside the seal to the electrode.

Systems for maintaining moisture in a textile electrode

A machine knittable hybrid yarn for providing conductive traces through a textile is disclosed. The hybrid yarn includes conductive wires coated with an insulating material and twisted together with a nonconductive yarn. The nonconductive yarn is from a strong, inelastic, and nonconductive fiber, such as a meta-aramid or para-aramid that protects the integrity of the conductive wire during knitting. The conductive wire can be copper-clad stainless steel or copper wire is coated with polyurethane, and the nonconductive yarn can have no-drip and no-drip properties to allow ablation of the hybrid yarn to remove the conductive yarn and insulating coating on the wire such that the ablated region becomes externally conductive and suitable for making an electrical contact. The hybrid yarn can be bonded with nylon or similar polymer after twisting.

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Providence, RI, United States of America

Anjali Khemani