GB2632145A - A wearable article including an arrangement of sensing nodes and a method of fabricating same - Google Patents

Abstract

A wearable article comprising a fabric layer with an electrical conductor 203, a device 201 mounted to the fabric later at a node 102 and including a connector which has a crimp connection to the electrical conductor. The mounted device may be additional components and circuitry. The conductor may have a waved portion and a straight portion and there may be multiple conductors arranged in parallel. The fabric layer may be a tape 215 and the article can have a plurality of nodes. A layer of encapsulant material and a gasket may be provided. The article may be a garment and can be used to transmit bio signal data. The approach is designed to make it easier to incorporate sensors.

Description

A WEARABLE ARTICLE INCLUDING AN ARRANGEMENT OF SENSING NODES AND A METHOD OF FABRICATING SAME

[0001] The present invention is directed towards a wearable article comprising a biosignal measuring apparatus for sensing biosignals from a wearer of the wearable article, and which incorporates a sensor assembly and the electronics module. The wearable article further comprises a bus arrangement of nodes configured to further sense biosignals or other parameters in relation to the wearer of the wearable article, such as movement and environmental factors. The electronics module is arranged to transmit biosignal data to the user electronics module or other remote device. The present invention is also directed towards a node assembly and a method of fabricating nodes and node assemblies for incorporation in the wearable article.

BACKGROUND

[0002] Wearable articles, such as garments, can incorporate sensors that include wearable electronics used to measure and collect information from a wearer. It is advantageous to measure biosignals of the wearer during exercise or whilst working. It may be useful to collect data on a wearer's movements, or environmental conditions.

100031 It is known to provide a garment, or other wearable article, to which an electronic device (i.e. an electronics module, and/or related components) is attached in a prominent position, such as on the chest or between the shoulder blades. Advantageously, the electronic device is a detachable device. The electronic device is configured to process the incoming signals, and the output from the processing is stored and/or displayed to a user in a suitable way 100041 A sensor senses a biosignal such as electrocardiogram (ECG) signals and the biosignals are coupled to the electronic device, via an interface. Sensors detecting movement or environmental conditions can also be used, instead of, in addition to biosignal sensors.

[0005] The sensors may be coupled to the interface by means of conductors which are connected to terminals provided on the interface to enable coupling of the signals from the sensor to the interface.

[0006] Electronics modules for wearable articles such as garments are known to communicate with mobile devices over wireless communication protocols such as Bluetooth and Bluetooth 0 Low Energy. These electronics modules are typically removably attached to the wearable article, interface with internal electronics of the wearable article, and comprise a Bluetooth antenna for communicating with the mobile device.

[0007] The electronic device includes drive and sensing electronics comprising components and associated circuitry, to provide the required functionality.

[0008] The drive and sensing electronics include a power source to power the electronic device and the associated components of the drive and sensing circuitry.

[0009] As already mentioned, it may be helpful to be able to determine the environment in which the wearable article and electronics module are being used in order that context can be given for the measurements, insights and information being collected.

BRIEF SUMMARY

[0010] According to a first aspect of the invention, there is provided a method of making a wearable article, the method comprising the steps of: providing a fabric layer; incorporating at least one electrical conductor as part of the fabric layer; providing a mount; attaching at least one electrical conductor to the mount; applying the mount and attached connector to the fabric layer such that the at least one connector is coincident with the at least one electrical conductor; and applying pressure to the mount such that the the at least one connector crimps the at least one electrical conductor to the mount.

[0011] The step of crimping may provide a permanent connection to the at least one electrical connector to the mount.

[0012] The step of crimping may attach the mount to the fabric layer.

100131 The mount may be a printed circuit board having at least one electrical terminal point and the step of crimping the at least one electrical conductor provides electrical coupling between the at least one conductor and the at least one electrical terminal point.

[0014] The step of incorporating at least one electrical conductor may comprise forming the at least one electrical conductor in a waved configuration, interspersed with sections in which the at least one electrical conductor has a straight configuration.

[0015] The step of incorporating at least one electrical conductor may comprise the step of incorporating at least two electrical conductors.

[0016] The at least two electrical conductors are arranged parallel with each other. 100171 The step of providing the fabric layer may comprise providing a fabric tape.

[0018] The method may further include the step of providing a layer of encapsulant on the fabric layer.

[0019] The method may include the step of providing a gasket on to the fabric layer prior o applying the mount to the fabric layer and applying the mount on the gasket such that the gasket is retained between the mount and the fabric layer.

[0020] The method may include the step of removing a portion of the layer of encapsulant at the regions where the at least one electrical conductor is straight.

[0021] The step of incorporating at least one electrical conductor as part of the fabric layer comprises providing the electrical conductor on the surface of the fabric layer. Alternatively, the step of incorporating at least one electrical conductor as part of the fabric layer comprises integrating the electrical conductor in the fabric layer.

100221 The method may include the step of providing a cover for the mount.

[0023] According to a second aspect of the invention, there is provided a wearable article having at least one node, the wearable article comprising: a fabric layer including at least one electrical conductor; at least one mount attached to the fabric layer, the at least one mount having at least one connector mounted thereon, whereby the at least one mount and attached connector is attached to the fabric layer at one of the at least one node such that the at least one connector is coincident with the at least one electrical conductor, and the at least one connector has a crimp connection to the at least one electrical conductor.

[0024] The mount may be crimped to the fabric layer by means of the at least one connector.

[0025] The mount may be a printed circuit board having at least one electrical terminal point and the at least one electrical conductor is electrically coupled to the at least one electrical terminal point by means of the crimp connection.

[0026] The mount may include additional components and associated circuitry.

[0027] The at least one electrical conductor may have a waved configuration, interspersed with sections in which the at least one electrical conductor has a straight configuration, the mount being coincident with the straight sections.

[0028] The wearable article may comprise at least two electrical conductors.

[0029] The at least two electrical conductors may be arranged parallel with each other.

[0030] The fabric layer may be a fabric tape.

100311 The wearable article comprise a plurality of nodes.

[0032] The wearable article my further comprise a layer of encapsulant on the fabric layer.

[0033] The wearable article may further include a gasket retained between the mount the fabric layer.

[0034] A portion of the layer of encapsulant may be removed at the sections where the at least one electrical conductor is straight.

[0035] The at least one electrical conductor may be provided on the surface of the fabric layer. Alternatively, the at least one electrical conductor as part of the fabric layer is integrated in the fabric layer.

100361 The wearable article may include at least one cover for the at least one node.

[0037] According to another aspect of the present invention there is provided a wearable article incorporating a wearable article of the second aspect of the invention.

[0038] The wearable article is of the second aspect is incorporated by means of bonding or sewing 100391 According to a fourth aspect of the present invention, there is provided an electronics module for use with the wearable article of the second aspect of the invention.

[0040] The electronics module comprises a housing and a plurality of connectors.

100411 The present invention provides for a simple way of easily and flexibly being able to manufacture a large number of nodes that can be used to incorporate sensors for sensing biosignals and other data on a persons movements, or environmental conditions. Nodes can be made on narrow fabric tape using a semi automated process and which can then be integrated into a larger wearable article. The nodes comprise a mount such as a printed circuit board which can be easily crimp connected to conductor provide in or on the fabric tape. The fabric tape with the nodes can then be cut and integrated into the larger wearable article. The crimping provides a robust and flexible node that can be coupled to an electronics module with additional functionality and which enables data and signals to be coupled to other nodes, to an additional processing hub, to other sensors or externally of the wearable article.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

100421 The invention will now be described with reference to the accompanying drawings, of which: [0043] FIG. 1 illustrates a wearable article incorporating sensing nodes in accordance with the invention; [0044] FIG. 2 is a perspective view illustrating an node assembly and node on a wearable article in accordance with a first embodiment of the present invention; [0045] FIG. 3 is a side view corresponding to the view in FIG. 2; [0046] FIG. 4 is a perspective view illustrating the node sensor module and node sensor module holder of the node assembly of FIG. 2; 100471 FIG. 5 is a perspective view illustrating the node sensor module of the node assembly of FIG. 2; [0048] FIG. 6 is a perspective view illustrating the node assembly of FIG. 2; [0049] FIG. 7 is a further perspective view illustrating the node assembly of FIG. 6 showing the placing of the electrical conductors; 100501 FIG. 8 is a perspective view illustrating the node PCB of the node assembly of FIG. 2; [0051] FIG. 9 is an exploded view illustrating the node assembly and fabric layer of FIG. 2; [0052] FIG. 10A is a perspective view illustrating the crimp connector of the node assembly of FIG. 2; [0053] FIG. I OB is a further perspective vie Ilustrating the crimp connector of the node assembly of FIG. 2; [0054] FIG. I OC illustrates a preformed sheet from the crimp connector FIG. 10A and FIG. I OB is made.

[0055] FIG. I I a perspective view illustrating the spring contact of the node assembly of FIG. 2; [0056] FIG. 12 is a perspective view illustrating an node assembly and node on a wearable article in accordance with a second embodiment of the present invention; [0057] FIG. 13 is a perspective view illustrating the node assembly of FIG. 12; [0058] FIG. 14 is a side view illustrating the node assembly of FIG. 12; [0059] FIG. 15A is an underside view illustrating the node assembly of FIG. 12; [0060] FTG. I 5B is an underside perspective view illustrating the node assembly of FTG. 12; 100611 FIG. 16 is an underside perspective view illustrating the node sensor module of the node assembly of FIG. 12; [0062] FIG. 17 is a polarity correcting circuit diagram; [0063] FIG. 18A is a perspective view of a crimping tool for use in fabricating a wearable article of the present invention; and [0064] FIG. 18B is a side view of a crimping tool for use in fabricating a wearable article of the present invention.

DETAILED DESCRIPTION

[0065] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

[0066] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the disclosure is provided for illustration purpose only and not for the purpose of limiting the disclosure as defined by the appended claims and their equivalents.

100671 It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0068] "Wearable article" as referred to throughout the present disclosure may refer to any form of device interface which may be worn by a user such as a smart watch, necklace, garment, bracelet, rings or other jewellery or glasses. The wearable article may be a textile article. The wearable article may be a garment The garment may refer to an item of clothing or apparel. The garment may be a top. The top may be a shirt, t-shirt, blouse, sweater, jacket/coat, or vest. The garment may be a dress, garment brassiere, shorts, pants, arm or leg sleeve, vest, jacket/coat, glove, armband, underwear, headband, hat/cap, collar, wristband, stocking, sock, or shoe, athletic clothing, personal protective equipment, including hard hats, a harness, swimwear, wetsuit or dry suit.

[0069] The wearable article can also include textile or fabric panels or narrow fabrics including ribbons or tapes and can be part of a larger wearable article.

[0070] The term "wearer" includes a user who is wearing, or otherwise holding, the wearable article.

[0071] The wearable article may be constructed from a woven or a non-woven material. The wearable article/garment may be constructed from natural fibres, synthetic fibres, or a natural fibre blended with one or more other materials which can be natural or synthetic. The yarn may be cotton. The cotton may be blended with polyester and/or viscose and/or polyamide according to the application. Silk may also be used as the natural fibre. Cellulose, wool, hemp and jute are also natural fibres that may be used in the wearable article/garment. Polyester, polycotton, nylon and viscose are synthetic fibres that may be used in the wearable article/garment.

[0072] The wearable article may be a tight-fitting garment. Beneficially, a tight-fitting garment helps ensure that the sensor devices of the garment are held in contact with or in the proximity of a skin surface of the wearer. The garment may be a compression garment. The garment may be an athletic garment such as an elastomeric athletic garment. The garment may also include an inner layer and an outer layer. The inner layer may be a compression garment and the outer less a loose-fitting garment.

[0073] The wearable article can be a workplace garment made of material suitable for a workplace environment, including environments such as healthcare facilities, factories, building environments, logistics warehousing. It may be made of a high visibility material and may be cut to allow for full ranges of movement.

100741 "Biosignal" as referred to throughout the present disclosure may refer to signals from living beings that can be continually measured or monitored. Biosignals may be electrical or non-electrical signals. Signal variations can be time variant or spatially variant.

[0075] Sensing components may be used for measuring one or a combination of bioelectrical, bioimpedance, biochemical, biomechanical, bioacoustics, biooptical or biothermal signals of the wearer 600. The bioelectrical measurements include electrocardiograms (ECG), electrogastrograms (EGG), electroencephalograms (EEG), photoplethysmography (PPG) and electromyography (EMG). The bioimpedance measurements include plethysmography (e.g., for respiration), body composition (e.g., hydration, fat, etc.), and electroimpedance tomography (ETT). The biomagnetic measurements include magnetoneurograms (MNG), magnetoencephalography (MEG), magnetogastrogram (MGG), magnetocardiogram (MCG). The biochemical measurements include glucose/lactose measurements which may be performed using chemical analysis of the wearer 600's sweat. The biomechanical measurements include blood pressure, and tracking of movements. The bioacoustics measurements include phonocardiograms (PCG). The biooptical measurements include orthopantomogram (OPG). The biothermal measurements include skin temperature and core body temperature measurements.

[0076] Environmental sensors may be temperature sensors, carbon monoxide sensors or other gas sensors, Movement sensors may include inertial measurement units (IMUs) and location sensors.

100771 There is shown an example system 107 according to aspects of the present disclosure. The system 107 comprises an electronics module 105, a wearable article 101 in the form of a garment, and a user electronic device, such as a mobile phone. The garment is worn by a user who in this embodiment is the of the wearable articles 101.

[0078] The electronics module 105 is arranged to couple with a number of sensing units incorporated into the wearable article 101 to obtain signals from the sensing units.

[0079] The electronics module 105 and the wearable article 101, including the sensing units, comprise a wearable assembly 108.

[0080] The sensing units comprise one or more sensors with associated conductors and other components and circuitry. For example, in the embodiment described herein, the sensing units comprise biosignal sensors 104 coupled to the electronics module 105 by means of conductive pathways 103.

100811 Sensing units are also arranged to be located at a number of nodes 102 located around the wearable article 101 and coupled in a network to the electronics module 105 by means of conductive pathways 103. In the embodiment described herein, the wearable article 101 is a long-sleeved top and the nodes 102 are five in number: one on each sleeve cuff, one on each upper sleeve portion and one located centrally on the neckline of the 101. In the embodiment described herein, five nodes are described, but any wearable article include fewer or many more.

[0082] The sensing units at the nodes 102 comprise node sensor modules 201 arranged along with the conductive pathways 103 in a bus arrangement to enable signals to be passed from one or more of the sensing units to the electronics module 105 when attached to the wearable article 101. The electronics module 105 may also include sensors including biosignals sensor.

[0083] The electronics module 105 is further arranged to wirelessly communicate data to the user electronic device 109. Various protocols enable wireless communication between the electronics module 105 and the user electronic device 109. Example communication protocols include Bluetooth ®, Bluetooth ® Low Energy, and near-field communication (NEC).

100841 The wearable article 101 has an electronics module holder 110 in the form of a pocket. The pocket or cover is sized to receive the electronics module 105. When disposed in the pocket, the electronics module 105 is arranged to receive sensor data from the sensing units at the nodes 102 via the conductive pathways 103. The electronics module 105 is therefore removable from the wearable article 101.

[0085] The present disclosure is not limited to electronics module holders in the form of pockets.

[0086] The electronics module 105 may be configured to be releasably mechanically coupled to the wearable article 101 as will be described below. The mechanical coupling or mechanical interface may be configured to maintain the electronics module 105 in a particular orientation with respect to the garment 200 when the electronics module 100 is coupled to the wearable article 101. This may be beneficial in ensuring that the electronics module 105 is securely held in place with respect to the wearable article 101 and/or that any electronic coupling of the electronics module 105 and the wearable (or a component of the wearable article 101) can be optimized. The mechanical coupling may be maintained using friction or using a positively engaging mechanism, for example.

[0087] Beneficially, the removable electronics module 105 may contain all the components required for data transmission and processing such that the wearable article 101 only comprises the sensing units e.g. the biosignal sensors 104 and the conductive pathways 106, as well as the nodes 102 and conductive pathways 103. In this way, manufacture of the wearable article 101 may be simplified. In addition, it may be easier to clean a garment 200 which has fewer electronic components attached thereto or incorporated therein. Furthermore, the removable electronics module 100 may be easier to maintain and/or troubleshoot than embedded electronics. The electronics module 100 may comprise flexible electronics such as a flexible printed circuit (FPC).

[0088] The electronics module 105 may be configured to be electrically coupled to the wearable article 101. The electronics module 105 may also be integrated with the wearable article 101. The electronics module 105 may include a power supply, such as a removable power pack. The electronics module 105 may be arranged for wireless or wired charging. The charger (not shown) may be portable.

[0089] FIG. 2 illustrates a node 102 comprising a node sensor module 2W attached to a fabric layer 202 of a wearable article. The node sensor module 201 includes sensing componentry and associated circuitry and forms one of the sensing units.

[0090] In the present embodiment, the wearable article is a fabric tape 215 that is component of a larger wearable article such as the garment shown in FIG. 1.

[0091] The fabric layer 202 can be an integral part of a wearable article 101 or can be in the form of a strap, for example, of an elastic strap, or any other form of wearable article.

[0092] The node sensor module 201 is arranged for coupling to conductive pathways 103 in the bus arrangement referred to above.

[0093] In the embodiment described herein, the conductive pathways comprises an electrical conductor 203 in the form of a first electrical conductor 203a, a second electrical conductor 203b and a third electrical conductor 203c. Other numbers of conductors can be used and will depend upon the application. In one example, with the three conductors, conductors 203a and 203b could be used for generic 1-wire communication (1-wire and ground). The third electrical conductor 203c could be used as a dedicated power for more power hungry nodes. It could also be used as an interrupt line for safety critical nodes, like proximity warning, so the host processor gets the alert without the latency of the bus. The third electrical conductor 203c could also be used for redundancy purposes. The electrical conductors 203 are provided on an upper surface 207 the fabric layer 202. Alternatively, they can be integrated within the fabric layer 202.

[0094] The first electrical conductor 203a, second electrical conductor 203b and third electrical conductor 203c are wires in the form of an insulated solid or stranded conductor, as is known in the art. The conductors 203a, 203b can also be conductive thread with insulation (either applied to the thread or provided by means of the weaving process). The electrical conductor 203 are attached to, or integrated in, the fabric layer 202 by any suitable means in a I0 wavy or sinusoidal arrangement to allow for stretching of the fabric layer 202 and to mitigate against the impact of this on signal degradation and motion artefacts.

[0095] The node sensor module 201 comprises a housing 208 which is arranged to house one or more sensing components along with associated electrical and electronics components and circuitry.

[0096] Sensing components may be used for measuring one or a combination of bioelectrical, bioimpedance, biochemical, biomechanical, bioacoustics, biooptical or biothermal signals of the wearer 600 as mentioned above.

[0097] The sensing components can be environmental sensors such as temperature sensors, carbon monoxide sensors or other gas sensors as well as optical sensors, for example cameras. The sensing components can be movement sensors and may include inertial measurement units (IMUs) and location sensors.

[0098] The node 102 also includes a node sensor module holder 206 to assist in retaining the node sensor module 201 in place. The node sensor module holder 206 can be a flexible pocket or a cover bonded to an upper surface 207 the fabric layer 202.

[0099] The node 102 also includes a node PCB 204 which is attached to the upper surface 207 of the fabric layer 202. The node sensor module holder 206 covers the node PCB 204. The node PCB 204 will be described in further detail below. The node PCB 204 provides for the coupling of signals between the electrical conductors 203 and the node sensor module 201, and specifically the components and circuitry housed within the housing 208 as will be described in detail below.

101001 In this embodiment, the node 102 is configured to be coupled to the first electrical conductor 203a and the second electrical conductor 203b, whilst the third electrical conductor 203c of the bus arrangement is not coupled to this node 102.

101011 Data from the node sensor module 201 (such as data from a sensor housed in the node sensor module 201) can be coupled to a respective one of the electrical conductors 203 coupled to the node sensor module 201 at the node 102. This data can then be coupled to the electronics module 105 via the bus arrangement, where it can be further processed and/or transmitted to the user electronic device 109 for display to a user for further processing.

[0102] The node sensor module 201, node sensor module holder 206 and node PCB 204 comprise a node assembly 213.

[0103] The node sensor module 201 includes a first contact 2I2a which is configured to be electrically-conductively coupled to the first electrical conductor 203a at the node 102, and a second contact 212b which is configured to contact be electrically-conductively coupled to the second electrical conductor 203b at the node 102. The coupling could be direct or via switching circuitry.

[0104] The node sensor module 201 also includes a locating pin 209 provided on a housing lower face 304 of the housing 208. The locating pin 209 is configured to locate the node sensor module 201 with respect to the node PCB 204.

101051 The housing 208 can be constructed of any suitable material, such as a plastics material or a metal as required by the application and use-case scenario. In the embodiment described herein, the housing 208 is square shaped with an upper face 314, a lower face 304, and a side walls 316. The first contact 212a and the second contact 212b extend outwardly from the lower face 304 of the housing 208.

[0106] FIG. 3 is a view of the node sensor module 201 inserted into the node sensor module holder 206 at a node 102 of the wearable article 101. As mentioned above, the node 102 can be formed on a wearable article that is a component of a larger wearable article. In the embodiment described herein, the component wearable article is a fabric tape 215 which can be fabricated separately and then integrated into the larger wearable article 101 such as a garment.

[0107] In the embodiment descried herein, the electrical conductors 203 are 30 AWG silicone coated wires, arranged in a wavy or concertinaed arrangement to enable the fabric layer 202 of the fabric tape 215 to stretch without putting strain on the wire. At points along the length of the fabric tape 215 the wires follow a straight portion (indicated by A in FIG. 2). The sections A where the electrical conductors 203 are straight are formed at regular intervals along the length of the ribbon. It is at these straight portions A that the nodes 102 will be formed by enabling the electrical conductors 203 to connect to the node sensor module 2W and in particular the node PCB 204. The node PCB 204 is provided at the node 102 with the electrical conductors 203 being sandwiched between the node PCB 204 and the upper surface 207 of the fabric layer 202.

[0108] The node sensor module holder 206 is attached to the fabric layer 202. In the present embodiment the node sensor module holder 206 is a hard cover, but could also be formed from a flexible material such as a fabric, for example, the same material as the fabric layer 202. The node sensor module holder 206 defines a pocket 302 or recess into which the node sensor module 201 is can be inserted.

[0109] The double-headed arrow of Fig 4A shows how the node sensor module 201 can be inserted into, and removed from, the node sensor module holder 206.

[0110] FIG. 5 and FIG. 6 are underside views of the node sensor module 201. The fabric layer 202, and node sensor module holder 206 are not shown for clarity.

[0111] The node sensor module 201 is arranged to contact the node PCB 204 by means of the contacts 2I2a, 2I2b extending from the lower face 304 of the housing 208 and which contact PCB terminals 205 on the PCB upper surface 308.

[0112] The locating pin 209 comprises a shaft 310 having a frusto-conical cross-section with a circular retaining lip 312. The locating pin 209 cooperates with a notch 802 in the node PCB 204 to locate and retain the housing 208 of the node sensor module 201 on the node PCB 204.

[0113] Extending from the PCB lower surfaces 306 are a pair of crimp connectors 210 which are used to crimp the wires of respective first electrical conductor 203a and second electrical conductor 203b. The crimp connectors 210 are configured to pierce the insulation of the wires and to secure the node PCB 204 to the electrical conductors 203 and provide an electrical conductive connection between the electrical conductors 203, the node PCB 204 and the circuitry and components housed within the housing 208 of the node sensor module 201. This is described further below.

[0114] Although the embodiment described herein shows the node PCB 204 used to mount the crimp connectors 210 and associated terminals, components and circuitry. The node PCB 204 acts as a mount for the crimp connectors 210 and to support the node sensor module 201. The mount could be a rigid or flexible plate instead of a PCB to support and mount the crimp connectors 210.

101151 FIG. 7 is a further underside view showing the electrical conductors 203 crimped using the crimp connectors 210.

[0116] FIG. 8 illustrates the node PCB 204. The node PCB 204 is a flexible PCB utilizing surface mounted technology, or could be any other form of mount arranged to carry relevant contacts and circuitry.

101171 The node PCB 204 is dimensioned to conform with that of the node sensor module 201. The node PCB 204 includes an elongate notch 802 arranged to receive the locating pin 209 and to hold the locating pin 209 within the notch 802, thus securing the node sensor module 201 against the node PCB 204. The node PCB 204 has a PCB upper surface 308 and a PCB lower surface 306. On the PCB upper surface 308, two PCB terminals 205 are provided: a first terminal point 205a and a second terminal point 205b, arranged either side of the notch 802. The terminal points 205a, 205b can be exposed regions plated with a conductive material such as gold. Alternatively, they can be surface mounted technology contact pads or through hole contact. The terminal points are electrically conductively coupled to the crimp connectors 210 extending from the PCB lower surface 306. The electrical coupling can be direct or through switching circuitry.

[0118] FIG. 9 is an exploded diagram of the node 102 showing the various components of the node assembly 213 and the fabric layer 202.

101191 FIG. 10A and FIG. 10B illustrate the crimp connector 210. FIG. 10C illustrates the fabrication of the crimp connectors 210 of FIG. 10A and FIG. 10B.

[0120] The crimp connector 210 is fabricated from an electrically-conductive material such as aluminium, phosphor bronze, a tin alloy or nickel plating. In the present embodiment, each crimp connector 210 comprises two pairs of crimping portions 1001 to match and collaborate with respective electrical conductor 203. The number of crimp connectors 210 will depend upon the numbers of electrical conductors 203 which are to be connected.

[0121] Each pair comprises a first crimping portion 1002a and a second crimping portion 1002b. The first crimping portion 1002a has a valley-shaped profile and the second crimping portion 1002b has a V-shaped profile. These profiles are formed from cooperating profiles formed by M-shaped cuts 1006 formed in a metal sheet 1004 sheet of the electrically-conductive material during fabrication. Prior to fabrication of the fabric tape 215, a plurality of crimp connectors 210 are fabricated from the metal sheet 1004 in which M-shaped cuts 1006 cuts are made. The portions of the metal sheet 1004 are deformed outwardly -as indicated by the arrows of FIG. 10C -along the dotted lines shown in FIG. 10C to form crimping portions 1001. A pair of M-shaped cuts 1006 forms a crimp connector. A gap 1008 is formed between the pair of crimping portions 1001. This gap 1008 can be used during construction of the fabric tape 215.

[0122] FIG. 11 illustrates the contacts 212a, 212b that are provided on the housing 208 to electrically-conductively connect the electrical conductors 203 to the internal components and circuitry of the node sensor module 201 via the crimp connectors 210 and the first terminal points 205a and the second terminal points 205b.

[0123] The first contact 212a and the second contact 212b are constructionally the same: one is illustrated in FIG. 11.

[0124] Any suitable form of contact could be used.

[0125] The first contact 212a and the second contact 212b each comprise a body portion 1101 and a spring contact 1102 extending from the body portion I I 01. The contacts 2I2a, 21 2b are formed of a flexible electrically-conducting material such as aluminium or copper so as to act as a spring biased contact, biased to an extended position. When the node sensor module 201 is brought into connection with the node PCB 204 by inserting the locating pin 209 into the notch 802, the first contact 212a and the second contact 212b contact the respective first terminal point 205a and second terminal point 205b and exert a force against the node PCB 204 which causes the lip 312 of the locating pin 209 to abut the PCB lower surface 306 and, as such, retain the node sensor module 201 in place against the node PCB 204. This is illustrated in FIG. 6.

[0126] If it is required to only enable electrical contact when the node sensor module 201 is in place, a microswitch can be provide on the node PCB 204 which is activated when the locating pin 209 passes over it and enables activation of the node sensor module 201. Instead of a microswitch, an optical switch, light gate, Hall Effect sensor, reed switch or magnetic switch could be used.

[0127] The fabric tape 215 is fabricated by forming the electrical conductors 203 on or within the to the fabric layer 202. The electrical conductors 203 have the waved configuration as discussed above apart from the straight portions where the nodes 102 are to be located. The straight portions are shown at A on FIG. 2. The electrical conductors 203 are formed parallel to each other and equidistantly spaced.

101281 The crimp connectors 210 are surface mounted on to the node PCB 204 and are arranged so that they are also arranged parallel to each and equidistantly spaced from the longitudinal axis 704 of the fabric tape 215 (as shown in FIG. 7) so that they will be coincident with the electrical conductors 203 when placed on the fabric layer 202.

[0129] The fabric tape is wound on a first reel 1812 of a crimping tool 1800 and across an insert block 1806 which includes a guide channel 1818 configured to receive the fabric tape 215 to guide and retain the fabric tape 215 in place as the node PCB 204 is attached to the fabric layer 202. A free end fabric tape 215 is then attached to the second reel 1814.

[0130] The first reel 1812 and second reel 1814 are rotatably mounted on respective reel support arms 1816. The second reel 1814 rotates so as to pull the fabric tape 215 in the direction of the arrow shown in FIG. 18A. As the fabric tape 215 is pulled along, the fabric tape 215 unwinds from the first reel 1812 and on to the second reel.

[0131] The node PCB 204 along with attached crimp connectors 210 is then placed on top of the fabric layer 202 at the straight portions A coincident with the electrical conductors 203 such that the crimp connectors 210 overlie the respective electrical conductors 203.

[0132] The crimping tool 1800 (shown in FIG. 18A and FIG. 18B) -in addition to the reels described above -includes a tool body 1802 which carries a piston 1810 on which a piston plate 1808 is mounted. The piston plate 1808 is arranged to move up and down in a reciprocating motion -see the arrow in FIG. 18B -so that the piston can move in and out of contact with a node PCB 204 as the fabric tape 215 moves along the guide channel 1818.

[0133] The crimping too is controlled for example by pneumatic control mechanism. The pistons piston 1810 is controlled to apply a pressure on the face of the node PCB 204 and particularly the crimp connectors 210 so that the first crimping portions 1002a and the second crimping portions 1002b break through the insulation of the wires of the electrical conductors 203 and crimp the exposed portions of the wires to the crimp connectors 210 forming an electrically-conductive connection between the metal wires and the crimp connector 210 and from there to the respective first terminal points 205a and second terminal points 2056.

[0134] As the crimping tool applies pressure and deforms the crimping portions 1001, the crimping portions 1001 will be forced through the fabric layer 202 further retaining the node PCB 204 against the fabric layer 202. Fig 3 illustrates this.

101351 The node sensor module holder 206 (if being used) is applied by bonding or sewing, or any other suitable means.

[0136] To incorporate the fabric tape 215 into a larger wearable article such as a garment, the required length of fabric tape 215 is cut and added to the garment in the required arrangement, for example using bonding or sewing as known to persons skilled in the art.

[0137] FIG. 12 to Fig. FIG. I 5B illustrate another embodiment of the present invention. Where like parts are used in this embodiment, the drawings use the same reference numbers as the embodiments described in relation to FIG. I to FIG. 11.

[0138] In this embodiment, the node sensor module 201 and the node sensor module holder 206 are the same as described in previous figures, except that the node sensor module 201 in this embodiment has two pairs of spring contacts 1102 as shown in FIG. 16, there is no locating pin on the housing 208, and the node PCB 204 has no notch.

[0139] In the embodiment shown in FIG. 12, the electrical conductors 203 comprise a wire comprising stainless steel thread integrated into the fabric layer 202 with a synthetic polymer encapsulant 1201 covering the electrical conductors 203 and the fabric layer 202. Other conductors can be used. At the node 102 a portion of the encapsulant 1201 is removed to expose the electrical conductors 203 which are configured to be straight at A, to allow a device to electrically connect to the wire.

[0140] The PCB lower surface 306 includes the crimp connectors 210 and additional components 1502. These components 1502 can include sort circuit protection, reverse battery correction, and/or polarity correcting circuits 1702. The components 1502 may also include a Hall effect sensor to switch on power and data to the PCB terminals 205.

101411 In the embodiment described herein, a gasket 1202 is provided around the edges of the node PCB 204. The gasket 1202 can be fabricated from foam to reduce electromagnetic interference (EMI). It has the additional advantage of providing an increased level of comfort for the wearer.

[0142] As an alternative, the node 102 can be used without a gasket 1202.

101431 In another embodiment, the encapsulant 1201 does not need to be removed at the node 102. The node PCB 204, along with a sensing unit and associated electronics and circuitry could be embedded within the encapsulant 1201, negating the need of an external device. If the encapsulant 1201 is a polymer has the correct optical properties, an optical sensor on the node PCB 204 could be integrated directly. Example of optical sensors are PPG or SPO2 sensors. Other sensors could include EMG or ECG sensors.

[0144] As shown in FIG. 16, rather than just a pair of contacts 2I2a, 2I2b, a second pair of contacts -a third contact 2I2c and a fourth contact 2I2d -are provided on the lower face 304 orthogonal to the pair of first contact 2I2a and second contact 2I2b. This enables the housing 208 -when of a square construction -to be inserted into the node sensor module holder 206 without having to take account of the orientation of the node sensor module 201 with respect to the node sensor module holder 206.

[0145] In this case polarity correcting circuitry would be required to be included in the circuitry of the node sensor module 201. An example polarity correcting circuit 1702 is shown in Fig. 14.

[0146] In the present disclosure, the electronics module may also be referred to as an electronics device or unit. These terms may be used interchangeably.

[0147] At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as 'component', module' or 'unit' used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term "comprising" or "comprises" means including the component(s) specified but not to the exclusion of the presence of others.

101481 All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0149] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0150] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims (24)

1. CLAIMSI. A method of making a wearable article, the method comprising the steps of: providing a fabric layer; incorporating at least one electrical conductor as part of the fabric layer; providing a mount; attaching at least one electrical conductor to the mount; applying the mount and attached connector to the fabric layer such that the at least one connector is coincident with the at least one electrical conductor; and applying pressure to the mount such that the the at least one connector crimps the at least one electrical conductor to the mount.
2. 2. A method according claim 1, wherein the step of crimping may provide a permanent connection to the at least one electrical connector to the mount.
3. 3. A method according claim 1 or 2, wherein the step of crimping attaches the mount to the fabric layer.
4. 4. A method according to any one of claims 1 to 3 any preceding claim, wherein the mount is be a printed circuit board having at least one electrical terminal point and the step of crimping the at least one electrical conductor provides electrical coupling between the at least one conductor and the at least one electrical terminal point.
5. 5. A method according to any one of claims 1 to 4, wherein the step of incorporating at least one electrical conductor comprises forming the at least one electrical conductor in a waved configuration, interspersed with sections in which the at least one electrical conductor has a straight configuration.
6. 6. A method according to any one of claims 1 to 5, wherein the step of incorporating at least one electrical conductor comprises the step of incorporating at least two electrical conductors.
7. 7. A method according to claim 6, wherein the at least two electrical conductors are arranged parallel with each other.
8. 8. A method according to any one of claims 1 to 7, wherein the step of providing the fabric layer comprises providing a fabric tape.
9. 9. A method according to any one of claims 1 to 8, wherein the step of incorporating at least one electrical conductor as part of the fabric layer comprises providing the at least one electrical conductor on the surface of the fabric layer or integrating the at least one electrical conductor in the fabric layer.
10. 10. A method according to any one of claims 1 to 8, wherein the step of incorporating at least one electrical conductor as part of the fabric layer comprises integrating the at least one electrical conductor in the fabric layer.
11. 11. A method according to any one of claims 1 to 10, wherein the method includes the step of providing a cover for the mount.
12. 12. A wearable article having at least one node, the wearable article comprising: a fabric layer including at least one electrical conductor; at least one mount attached to the fabric layer, the at least one mount having at least one connector mounted thereon, whereby the at least one mount and attached connector is attached to the fabric layer at one of the at least one node such that the at least one connector is coincident with the at least one electrical conductor, and the at least one connector has a crimp connection to the at least one electrical conductor.
13. 13. A wearable article according to claim 12, wherein the mount is crimped to the fabric layer by means of the at least one connector.
14. 14. A wearable article according to claim 12 or 13, wherein the mount is a printed circuit board having at least one electrical terminal point and the at least one electrical conductor is electrically coupled to the at least one electrical terminal point by means of the crimp connection.
15. 15. A wearable article according to any one of claims 12 to 14, wherein the mount includes additional components and associated circuitry.
16. 16. A wearable article according to any one of claims 12 to 15, wherein the at least one electrical conductor has a waved configuration, interspersed with sections in which the at least one electrical conductor has a straight configuration, the mount being coincident with the straight sections.
17. 17. A wearable article according to any one of claims 12 to 16, wherein the wearable article comprises at least two electrical conductors.
18. 18. A wearable article according to claim 17, wherein the at least two electrical conductors are arranged parallel with each other.
19. 19. A wearable article according to any one of claims 12 to 18, wherein the fabric layer is a fabric tape.
20. 20. A wearable article according to any one of claims 12 to 19, wherein the wearable article comprises a plurality of nodes.
21. 21. A wearable article according to any one of claims 12 to 20, further comprises a layer of encapsulant on the fabric layer.
22. 22. A wearable article according to any one of claims 12 to 21, further ncluding a gasket retained between the mount the fabric layer.
23. 23. A wearable article according to any one of claims 12 to 22, wherein at least one electrical conductor is provided on the surface of the fabric layer.
24. 24. A wearable article according to any one of claims 12 to 23, wherein the at least one electrical conductor as part of the fabric layer is integrated in the fabric layer.