Sensor chain devices and methods

Abstract

Methods of manufacturing a chain segment having wires that connect various electrical devices and connectors together are disclosed. The wires are arranged in a pattern to facilitate strain relief. The wires, electrical devices, and connectors are encased in an injection molded material, and they are preferably coupled with a flexible material such as a fabric that can be stitched into a garment. The chain segment facilitates collection of movement data when stitched into an article of clothing. A method of manufacturing the chain segment that is modular to enable different configurations and different lengths of chains.

What is claimed is: 
     
         1 . A method of manufacturing a segment of a chain of electrical devices that is semi-flexible, comprising:
 arranging a first wire mold module and a first electrical device mold module according to a chain design;   disposing a first set of wires into the first wire mold module;   disposing a first electrical device into the first electrical device mold module;   coupling the first set of wires with the first electrical device;   injecting a first material into the first wire mold module to encase the first set of wires in place; and   injecting a second material into the first electrical device mold module to encase the first electrical device in place with respect to the first set of wires.   
     
     
         2 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , wherein the first material is a soft silicone. 
     
     
         3 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , wherein the second material is a hard silicone. 
     
     
         4 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , further comprising the step of curing the first material and the second material in a pressure tube. 
     
     
         5 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , further comprising:
 arranging a second wire mold module adjacent to the first wire mold module;   positioning the first set of wires in the second wire mold module; and   injecting the first material into the second wire mold module to encase the first set of wires in place.   
     
     
         6 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , further comprising:
 providing access to a second wire mold module and a second electrical device mold module;   arranging the second wire mold module and the second electrical device mold module according to the chain design;   disposing a second set of wires into the second wire mold module;   disposing a second electrical device into second first electrical device mold module;   coupling the second set of wires with the second electrical device and also with the first electrical device;   injecting the first material into the second wire mold module to encase the second set of wires in place; and   injecting the second material into the second electrical device mold module to encase the second electrical device in place with respect to the second set of wires.   
     
     
         7 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 1 , wherein the first wire mold module comprises a plurality of protrusions to hold the set of wires in a pattern. 
     
     
         8 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 7 , wherein the pattern is S-shaped. 
     
     
         9 . The method of manufacturing a segment of a chain of electrical devices that is semi-flexible of  claim 7 , wherein the pattern is Z-shaped.