Multi-material fibers and methods of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11951672-B2
Application number	US-202117236351-A
Country	US
Kind code	B2
Filing date	Apr 21, 2021
Priority date	Apr 24, 2020
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

Methods of manufacturing multi-material fibers having one or more electrically-connectable devices disposed therein are described. In certain instances, the methods include the steps of: positioning the electrically-connectable device(s) within a corresponding pocket provided in a preform material; positioning a first electrical conductor longitudinally within a first conduit provided in the preform material; and drawing the multi-material fiber by causing the preform material to flow, such that the first electrical conductor extends within the multi-material fiber along a longitudinal axis thereof and makes an electrical contact with a first electrode located on each electrically-connectable device. A metallurgical bond may be formed between the first electrical conductor and the first electrode while drawing the multi-material fiber and/or, after drawing the multi-material fiber, the first electrical conductor may be located substantially along a neutral axis of the multi-material fiber.

First claim

What we claim is:

1. A method of manufacturing a multi-material fiber comprising at least one electrically-connectable device, the method comprising the steps of:
positioning a first electrical conductor longitudinally within a first conduit provided in a preform material;
drawing the multi-material fiber by causing the preform material to flow;
creating at least one pocket in the drawn multi-material fiber to expose the first electrical conductor;
positioning an electrically-connectable device within the pocket, such that a first electrode on the electrically-connectable device is aligned with the first electrical conductor;
forming a metallurgical bond between the first electrical conductor and the first electrode; and
filling the pocket with a material to protect the electrically-connectable device.

2. The method of claim 1 further comprising positioning a second electrical conductor longitudinally within a second conduit provided in the preform material.

3. The method of claim 2 , wherein the at least one pocket further exposes the second electrical conductor and the electrically-connectable device is positioned within the pocket such that a second electrode on the electrically-connectable device is aligned with the second electrical conductor.

4. The method of claim 3 further comprising forming a metallurgical bond between the second electrical conductor and the second electrode.

5. The method of claim 1 , wherein creating the pocket comprises removing preform material.

6. The method of claim 5 , wherein removing preform material comprises using at least one of:
a laser; or
a milling machine.

7. The method of claim 1 , wherein the pocket is filled with one or more of an encapsulant or a photocured epoxy.

8. The method of claim 1 further comprising minimizing fluctuation of an outer diameter of the drawn multi-material fiber.

9. The method of claim 1 further comprising, before the electrically-connectable device is positioned within the pocket, coating the first electrode with a bonding material.

10. The method of claim 1 further comprising interlacing the drawn multi-material fiber with a plurality of additional fibers to form a textile.

11. The method of claim 10 further comprising:
removing preform material in a first drawn multi-material fiber in the textile to expose electrical conductors of the first drawn multi-material fiber;
removing preform material in a second drawn multi-material fiber that, in the textile, intersects the first drawn multi-material fiber to expose electrical conductors of the second drawn multi-material fiber; and
interconnecting the electrical conductors of the first drawn multi-material fiber to the electrical conductors of the second drawn multi-material fiber.

12. The method of claim 11 , wherein interconnecting the electrical conductors of the first drawn multi-material fiber to the electrical conductors of the second drawn multi-material fiber comprises inserting one or more of an interposer or a transposer therebetween.

Assignees

• Advanced Functional Fabrics Of America Inc
• Massachusetts Inst Technology

Inventors

• Chung Chia-Chun
• Cox Jason
• Mccarthy Kristina
• Mulherin Kristen
• Nguyen Jimmy
• Rein Michael
• Bernasconi Matthew
• Cantley Lauren
• Parameswaran Lalitha
• Rickley Michael
• Stolyarov Alexander

Classifications

• B23K1/0016

  Soldering of electronic components · CPC title

• B29C51/004 Primary

  Textile or other fibrous material made from plastics fibres (combined with plastic layers B29C51/145; compression moulding of reinforced plastic articles in matched moulds B29C70/46; using pressure difference B29C70/44) · CPC title

• B29C51/12

  of articles having inserts or reinforcements · CPC title

• B29D11/00701

  having an intermediate layer between core and cladding · CPC title

• B29D11/00721

  involving preforms for the manufacture of light guides · CPC title