Stretchable conductor circuit

Abstract

This disclosure provides a stretchable conductor structure, a garment with a stretchable conductor structure, and a method for producing a stretchable conductor structure. The conductive structure includes a set of conductive wires and a stretchable laminate. The set of conductive wires, each including a protective surface, the set of conductive wires patterned in a mesh structure to accommodate a manipulation while providing electrical conductivity across the set of conductive wires. The stretchable laminate encapsulates the mesh structure, the stretchable laminate can return the mesh structure of the set of conductive wires to an original state after the manipulation.

1 . A stretchable conductor structure comprising:
 a set of conductive wires, each including a protective surface, the set of conductive wires patterned in a mesh structure to accommodate a manipulation while providing electrical conductivity across the set of conductive wires; and   a stretchable laminate encapsulating the mesh structure, the stretchable laminate configured to return the mesh structure of the set of conductive wires to an original state after the manipulation.   
     
     
         2 . The conductor structure of  claim 1 , wherein:
 the mesh structure comprises:
 a first portion of the set of conductive wires aligned in a weft direction, and 
 a second portion of the set of conductive wires aligned in a warp direction, 
   the first portion and the second portion of the set of conductive wires cross each other to form a plurality of contact points,   adjacent contact points of the plurality of contact points have alternate overlaps of the first portion and the second portion of the set of conductive wires, and   diagonal contact points of the plurality of contact points have same overlaps of the first portion and the second portion of the set of conductive wires.   
     
     
         3 . The conductor structure of  claim 2 , wherein:
 the manipulation is a stretching that occurs at an angle relative to the weft direction and the warp direction,   a first distance, between the diagonal contact points aligned with the direction of the stretching, increases with the manipulation, and   a second distance, between the diagonal contact points perpendicular to the direction of the stretching, decreases with the manipulation.   
     
     
         4 . The conductor structure of  claim 3 , wherein the first distance and the second distance are the same distance in the original state of the mesh structure. 
     
     
         5 . The conductor structure of  claim 1 , further comprising a stretchable electrically conductive coating patterned on the mesh structure. 
     
     
         6 . The conductor structure of  claim 1 , wherein the protective surface is composed of a material that provides protection from corrosion and oxidation. 
     
     
         7 . The conductor structure of  claim 1 , wherein the protective surface is a nickel/gold plating. 
     
     
         8 . The conductor structure of  claim 1 , wherein the stretchable laminate is an electrical insulator for the set of conductive wires in the mesh structure. 
     
     
         9 . The conductor structure of  claim 1 , wherein the mesh structure includes the conductive wires patterned using a meandering horseshoe pattern. 
     
     
         10 . A garment comprising:
 a fabric; and   a flexible conductor circuit disposed within or adjacent to the fabric, the flexible conductor circuit comprising:
 one or more circuit components; and 
 a stretchable conductor structure connecting the one or more circuit components, the stretchable conductor structure comprising:
 a set of conductive wires, each including a protective surface, the set of conductive wires patterned in a mesh structure to accommodate a manipulation while providing electrical conductivity across the set of conductive wires; and 
 a stretchable laminate encapsulating the mesh structure, the stretchable laminate configured to return the mesh structure of the set of conductive wires to an original state after the manipulation. 
 
   
     
     
         11 . The garment of  claim 10 , wherein:
 the mesh structure comprises:
 a first portion of the set of conductive wires aligned in a weft direction, and 
 a second portion of the set of conductive wires aligned in a warp direction, 
   the first portion and the second portion of the set of conductive wires cross each other to form a plurality of contact points,   adjacent contact points of the plurality of contact points have alternate overlaps of the first portion and the second portion of the set of conductive wires, and   diagonal contact points of the plurality of contact points have same overlaps of the first portion and the second portion of the set of conductive wires.   
     
     
         12 . The garment of  claim 11 , wherein:
 the manipulation is a stretching that occurs at an angle relative to the weft direction and the warp direction,   a first distance, between the diagonal contact points aligned with the direction of the stretching, increases with the manipulation, and   a second distance, between the diagonal contact points perpendicular to the direction of the stretching, decreases with the manipulation.   
     
     
         13 . The garment of  claim 12 , wherein the first distance and the second distance are the same distance in the original state of the mesh structure. 
     
     
         14 . The garment of  claim 10 , further comprising a stretchable electrically-conductive coating patterned on the mesh structure. 
     
     
         15 . The garment of  claim 10 , wherein the protective surface is composed of a material that provides protection from corrosion and oxidation. 
     
     
         16 . The garment of  claim 10 , wherein the protective surface is a nickel/gold plating. 
     
     
         17 . The garment of  claim 10 , wherein the stretchable laminate is an electrical insulator for conductive wire in the mesh structure. 
     
     
         18 . The garment of  claim 10 , wherein the mesh structure includes the conductive wires patterned using a meandering horseshoe pattern 
     
     
         19 - 22 . (canceled)