Weft Knit Fabric with Electrical Components

Abstract

Knitting equipment may be used to form weft knit fabric. A conductive strand may be coupled to a weft knit fabric layer using stitches such as tuck stitches, knit stitches, and floats. An electrical component may be mounted to a float and electrically connected to the conductive strand. A double knit fabric may include first and second outer weft knit layers joined by a connecting strand. The electrical component may be mounted to an outer weft knit layer or the connecting strand. The electrical component may have first and second portions that attach together to trap a conductive strand between the first and second portions. The electrical component may have a through-hole that receives a conductive loop in the fabric. A circular knit fabric may include a conductive strand that spirals around a longitudinal axis and that has connected segments and electrically isolated segments.

What is claimed is: 
     
         1 . A weft knit fabric, comprising:
 non-conductive strands that form an outer weft knit layer;   a conductive strand interlaced with the non-conductive strands, wherein the conductive strand comprises a float between first and second stitches; and   an electrical component mounted to the float and electrically coupled to the conductive strand.   
     
     
         2 . The weft knit fabric defined in  claim 1  wherein the first and second stitches comprise tuck stitches. 
     
     
         3 . The weft knit fabric defined in  claim 1  wherein the first and second stitches comprise knit stitches. 
     
     
         4 . The weft knit fabric defined in  claim 1  wherein the float passes over at least two loops in the outer weft knit layer. 
     
     
         5 . The weft knit fabric defined in  claim 1  further comprising an additional outer weft knit layer interlaced with the outer weft knit layer, wherein the electrical component is interposed between the outer weft knit layer and the additional outer weft knit layer. 
     
     
         6 . The weft knit fabric defined in  claim 5  further comprising connecting strands that travel back and forth between the outer weft knit layer and the additional outer weft knit layer. 
     
     
         7 . The weft knit fabric defined in  claim 6  further comprising a pocket formed between the outer weft knit layer and the additional outer weft knit layer. 
     
     
         8 . The weft knit fabric defined in  claim 7  wherein the connecting strands are located on opposing sides of the pocket. 
     
     
         9 . The weft knit fabric defined in  claim 1  wherein the electrical component has first and second portions and wherein the conductive strand is interposed between the first and second portions. 
     
     
         10 . The weft knit fabric defined in  claim 9  wherein the first and second portions are coupled together using attachment structures selected from the group consisting of: snaps, clips, adhesive, magnets, and screws. 
     
     
         11 . A weft knit fabric, comprising:
 first and second outer weft knit layers;   a conductive strand that travels back and forth between the first and second outer weft knit layers; and   an electrical component mounted to the conductive strand and interposed between the first and second outer weft knit layers.   
     
     
         12 . The weft knit fabric defined in  claim 11  wherein the electrical component comprises a plated through-hole that receives the conductive strand. 
     
     
         13 . The weft knit fabric defined in  claim 12  wherein the plated through-hole has sloped sides. 
     
     
         14 . The weft knit fabric defined in  claim 11  wherein the first and second outer weft knit layers comprise non-conductive strands. 
     
     
         15 . The weft knit fabric defined in  claim 11  wherein the electrical component has first and second portions and attachment structures that attach the first portion to the second portion, wherein the attachment structures are selected from the group consisting of: snaps, clips, adhesive, magnets, and screws. 
     
     
         16 . A weft knit fabric, comprising:
 strands that form courses of loops, wherein the strands comprise a conductive strand that forms a conductive loop in the courses of loops; and   an electrical component having a through-hole that receives the conductive loop, wherein the conductive loop has first and second conductive loop segments that are electrically isolated from one another and wherein the electrical component has a first electrode coupled to the first conductive loop segment and a second electrode coupled to the second conductive loop segment.   
     
     
         17 . The weft knit fabric defined in  claim 16  wherein the weft knit fabric comprises a circular knit fabric. 
     
     
         18 . The weft knit fabric defined in  claim 17  wherein the circular knit fabric loops around a longitudinal axis and wherein the conductive strand spirals at least partially around the longitudinal axis. 
     
     
         19 . The weft knit fabric defined in  claim 18  wherein the conductive strand has a first pair of segments that are joined by an electrical connection and a second pair of segments that are electrically isolated from one another. 
     
     
         20 . The weft knit fabric defined in  claim 16  wherein the weft knit fabric comprises a double knit fabric having first and second weft knit layers.