DESC:FIELD OF THE INVENTION
The present invention relates to electroluminescence based woven fabric.
BACKGROUND OF THE INVENTION
Electroluminescence (henceforth referred as EL) is an optical and electrical phenomenon in which a material emits light in response to the passage of an electric current or to a strong electric field. These materials are generally referred as phosphor and generate one to multiple colors of varying intensity based on the electrical input. Unlike LED the EL phenomenon does not produce heat, however needs a specific driving circuit to work. EL provides an advantage as it can be made into a thin flat surface, referred to as EL panel or stripes or even a thing strand called EL wire. A typical EL system needs an EL lighting component (panel, strip, wire), driver for EL and a power source. EL driver may have functionality for changing intensity & blink rate / type.
Electroluminescing fibers have been known generally in the art, but few have been produced beyond a test scale. Generally, such Electroluminescing fibers may contain a material, such as a phosphor, that luminesces in an electric field. Such fibers, however, face a series of problems, including low reliability. These fibers also lack sufficient flexibility to be made into one-, two-, and three-dimensional light emitting objects using textile fabrication technologies such as knitting, weaving, braiding, etc., that use raw materials in filamentary form.
Further, there are known woven electroluminescent panels which comprise flexible wires or filaments that are woven into a fabric structure. These wires or filaments are the basic building block for the final structure and usually comprise a pair of electrodes with electroluminescent phosphor embedded there between and an outer coating to bond the electrodes and phosphor together. Before the weaving of the wires or filaments, fabrication of the wires or filaments is essential. This is done by combining the electrodes and the electroluminescent phosphor, however this procedure is expensive and time consuming. Further, getting the wires or filaments of the desired fine thickness is another problem while generating said wires.
Accordingly, there is a need for an effective process of integration of electroluminescence wire based lighting system in woven fabric that overcome the drawbacks of the prior art and provides full proof method of integration of EL based products as inherent part of woven fabric in order to achieve a uniformity, repeatability, design flexibility, quality finish in from and back of substrate and a mass production technique for commoditizing the finished products.

SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method for integrating an electroluminescence (EL) wire with a fabric. In a first step, the EL wire is feed from an unwinding creel. A creel tension of said EL wire is maintained in the range of 100 cN to 210 cN and beaming tension of said EL wire is of about 20000 N. In the next step, said EL wire is woven along with a plurality of warp yarns to form a fabric having a portion of EL wire free at a seam of the fabric weave.
In another aspect, the present invention provides a method of manufacturing a garment of the EL wire integrated fabric. In the first step, the EL wire integrated fabric is cut in required dimensions. In the next step, the insulation of the free portions of the EL wire is stripped. In the next step, the free portion of EL wire is placed in the EL wire contact point of a T-connector such that EL wire core makes contact with EL wire core contact point of the T-connector and EL wire flexible strand makes contact with EL wire flexible strand point of the T connector. In the next step, the wire connections of the EL wire core and EL wire flexible strand to respective contact blades having push switches. In the next step, the connection extending from the contact blades are connected to the EL wire driver. In the next step, the garment is stitched by positioning the T connector along with the EL driver in seam.
In yet another aspect of the present invention, a system for integrating an EL wire of the fabric is provided. The system includes at least one T-connector for connecting the EL wire with the EL wire driver. The T-connector has a housing. The housing includes a power source supply slots and the EL wire contact portion configured on a surface thereof. The EL wire contact portion includes the EL wire flexible strand contact point that encloses the EL wire core contact point. The EL wire connections extending from the EL wire flexible band contact point and the EL wire core contact point connect to a plurality of contact blades positioned within the housing of the T connector. The contact blades have a push switches configured therewith.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a T-connector for an Electroluminescence i.e. EL wire in accordance with an embodiment of the present invention;
FIG. 2 shows the T-connector and a blade contactor engaged (A) and disengaged mode (B) to make connection in accordance with an embodiment of the present invention;
FIG. 3 shows cross sectional view of T-connector of FIG. 1;
FIG. 4 shows wiring of T-connector in accordance with an embodiment of the present invention;
FIG. 5A shows photographic representation of EL wire woven as weft in cotton rich fabric in accordance with an embodiment of the present invention; and
FIG. 5B shows the EL wire woven as weft in cotton rich of FIG. 5Afabric lit on power supply.
DETAILED DESCRIPTION OF THE INVENTION
Although specific terms are used in the following description for sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings, and are not intended to define or limit the scope of the invention.
In general aspect, the present invention discloses a process of integration of electroluminescence wire (hereinafter refereed as “EL wire”) based lighting system in woven fabric. The process involves integration of lighting substance such as an onto flexible substrates like textiles, leather, foam, polymer sheets and products made from such materials like garments, shoes, seating, home furnishing, protective clothing etc.
In another aspect, the present invention relates to a process of achieving lighting by integrating electroluminescent based products in the woven fabric during the weaving process on a commercial weaving machine. In yet another aspect, the present invention relates to a process of preparation of an EL wire as a warp.

Referring to FIG. 1-3, a T-connector (100) in accordance with an embodiment is shown. In this one embodiment, the T-connector (100) has an EL wire contact portion (101) connected to a body housing (105). The EL wire contact portion (101) includes an EL wire flexible strand contact point (102) that encloses an EL wire core contact point (104). The wire connections (106) of the EL wire flexible strand point (102) the EL wire core contact point (104) are connected to contact blades (108) having push switches (110) configured therewith. The body housing (105) has AC supply housing (112) configured on one of the walls thereof.
Referring to FIG. 1 to 4 a process of integration of electroluminescence wire based lighting system in woven fabric in operation is disclosed. In a first step, the EL wire is feed from an unwinding creel. In the next step, the EL wire is woven in the fabric thereby leaving a portion of EL wire free from a fabric weave. In the next step, the insulation of the free portions of the EL wire is stripped. In the next step, the free portion of EL wire is placed in the EL wire contact point of a T-connector such that EL wire core (202) makes contact with EL wire core contact point (104) of the T-connector (100) and EL wire flexible strand (205) makes contact with EL wire flexible strand point (102) of the T connector (100). In the next step, the EL wire (200) is connected to an EL wire driver (201). In the next step, the wire connections of the EL wire core (202) and EL wire flexible strand (205) to respective contact blades (108) having push switches (110). In next step, the connections extending from the contact blades (108) are connected to the EL driver (201) through power supply slots (112) thereof. In the next step, the seam is closed using fabric with which the EL wire is integrated. The EL wire driver (201) may or may not be enclosed in seam of garment.
In accordance with an embodiment, the stripped EL wire (200) is placed in a T-connector (100). The T-connector (100) creates insulation between the EL wire core (202) and EL Wire Insulation (204) with bent flexible strand (205) and provides a separate connection to not the strands that is used further to supply power. A common power supply cable (114) is connected to all the T-connector (100) on the seam. However, it is understood here that an individual power supply arrangement may be made to the each T-connector (100) achieving a better control over a lighting sequence. It is understood here that the power supply is connected once the fabric is cut in a desired pattern.
In accordance with this one embodiment, the T-connector (100) consists of a plurality of concentric metallic tubes with an insulation placed there between and on the outer side thereof. An outer metallic tube grips the flexible copper strand (205) and an inner metallic tube houses the core copper strand (202). A wire connections of the flexible copper strand and the core copper strand are correspondingly connected to a respective blades (108) type metal contactor. The blade (108) type contactors are pushed in order to get locked, cut through the insulation of the connecting wire and make contact between the EL wire (200) and the connecting wire. A portion connecting wire (114), which connecting to the EL wire (200) has a heat shrinkable polymer as the outer sheath that shrinks on application of heat and holds the EL wire (200) in place.
In accordance with this one embodiment, once the connection is done, a seam is closed using an extra fabric tape. The extra fabric tape goes on the front and back of the seam, thereby hiding the connection. Such arrangements can be done on the bottom of pants, shirts, jackets, curtains etc. Folding and sewing of seam may also be done, however the sharp bending at the seam may result in breaking of the EL wire (200) during use of garment. This method may work well in many applications where fabric at the seam or edge are not subjected to stress and strain.
Referring to FIGS. 1-4, the connecting wire (114) from the T-connector (100) links the EL wires (200) to an EL wire driver (201). The EL wire driver (201) controls the sequence, timing, pattern and brightness of the EL wire (200). Thus the EL wire (200) may be lit in a sequence, for certain period of time with a predefined blinking patterns at various brightness that is either preprogramed on to a chip in EL driver (201) or is communicated to the EL driver (201) via a wireless signal such as BLE Wi-Fi based communication device or sensor data. The communication device includes Smartphone or tab or i-pad, laptop or computer. The sensors such as brightness sensor, noise level sensor or direction sensor may be used. It is to be noted here that there is no inter meshing or communication between products like two garments, instead a user Smartphone is used to control and monitor the EL lighting system as an advance option to use the EL based product.
In accordance with an embodiment, the Smartphone has an application installed therein for communication with the EL wire driver (201). The working of EL wire knitted in the garment is controlled by communication between the EL wire driver having chip installed therein and the Smartphone having the application. The application includes different toggles for controlling intensity of glow, time intervals for lighting of the EL wire (200) and color of EL wire (200). However, the working of EL wire (200) may also be controlled by a switch positioned on the EL wire driver (201). In this method, there is no need of WIFI or connections. It is to be noted here that one or more EL wire drivers (201) may be used for controlling working of the EL wire.
The EL driver (201) used herein may be powered by non-rechargeable or rechargeable batteries. The batteries include the standard ones available in market or thin flexible batteries with large surface area stitched directly on to the fabric and connected to the EL driver (201) via wires, conductive traces, conductive threads etc. The EL driver (201) may also be powered by connecting it to a mobile phone via a cable hidden in seams or clothing and attachment port opening inside the pocketed wire when used for a longer length may also be powered via an external AC source and the EL driver (201) designed for AC power source (like in home furnishing application).
Referring to FIGS. 5A and 5B, photographic representation of EL wire (200) woven and lit as weft in cotton rich fabric in accordance with an embodiment of the present invention is shown.
In accordance with the present invention, the materials are selected from the group of flexible materials such as textiles, leather, foam, polymer sheets and the like. The EL wire (200) has a diameter from about 0.6 mm to about 1 mm. For using the EL wire (200) as a warp, the EL wire spools is mounted on an unrolling creel of a sectional warping machine along with a base yarn of which the fabric is to be made. The base yarn along with the EL wire (200) is warped on a drum with sufficient tension. In this one embodiment a creel tension is maintained at approximately 110 cN per thread and a beaming tension is approximately 20000N in order to make a usable yarn beam. However it is understood here that the creel tension and the beaming tension may vary in alternative embodiments of the present invention.
In another embodiment of the present invention, a process of integration of EL wire (200) based lighting system in woven fabric is disclosed. The process comprises: weaving of an EL wire (200) with a material to produce lighting effect. In a next step, weaving of the EL wire (200) is done as a warp or as a weft in a woven fabric. Warping step is achieved by mounting the EL wire (200) spools on an unrolling creel of a sectional warping machine along with a base yarn of which the fabric is to be made. Further step involves warping of a base yarn along with the EL wire (200) on a drum with a predefined tension.
In alternative embodiments, a process of preparation of an EL wire (200) as a warp is disclosed. The process comprises: feeding an EL wire (200) directly on the weaving loom as an individual warp thread, while the base warp yarn is delivered from the beam. Feeding of the EL wire (200) is done from top unwinding creel to the weft feeder. The EL wire (200) is then transferred to the selector. In a final step, the wire is transferred to a plurality of rigid rapiers which takes the yarn from one end of the fabric to another.
In this one embodiment a creel tension is maintained at approximately 110 cN per thread and a beaming tension is approximately 20000N in order to make a usable yarn beam. However it is understood here that the creel tension and the beaming tension may vary in alternative embodiments of the present invention. It is to be noted here that the placement of Electroluminescence warp wire in warping and weaving depends on the requirement of the pattern. The weaving is carried out on a rigid rapier heavy duty machine that is capable of handling the thick EL wire (200).
In accordance with the embodiment of the present invention, the weft yarn is cut by using a mechanical cutter. A gluing applicator is placed to insulate the ends of the EL wire (200). This ensures easy processing of fabric without damage to the EL wires (200). In cases where wet process is not required the cut weft may be kept as is without performing gluing.
In accordance with alternative embodiments of the present invention, a leno based structure with only EL wire (200) as weft may be used to make see through fabric having lighting capability. Such fabrics may be used for architecture and furnishing applications. The fabric once ready after weaving and processing may be used to make garment. During the garment making process the EL wire (200) orientation in the garment needs to be predefined before cutting and seam allowance plus extra seam allowance of 1/4th inch needs to be kept for mounting connectors at the end of the EL wire (200). On the seam, two cuts are made on either side of the EL wires (200) to free it from the fabric weave. Then with the help of a hot blade cutter (thermal wire stripper) the PVC cover or insulation (204) of the each EL wire (200) is stripped off to 1/8th inch. The EL wire (200) is distributed uniformly such that effect is limited to the lines of light where the weft yarn is used.
The flexible copper strand (205) is pulled back on the EL wire (200). It is to be noted that a very thin coating is used in the form of a flexible wire. The ratio of flexible wire to base yarn provides appropriate flexibility to the base fabric. Suitable range of 1 EL wire per inch to 4 EL wire per inch and suitable range of base yarn from 20 per inch to 50 per inch. The core copper strand (202) coated with phosphor is then ground to expose the copper. The PVC cover acts as a protecting insulation (202) thereby eliminating possibility of direct contact of phosphorous with skin.
The fabric thus made has the EL wire (200) integrated in them either in the warp or the weft direction or in both the directions. It is understood here that suitable effects may be given by using different weaves. A jacquard equipped loom may be used to ensure the EL wire (200) exposure in the fabric face as per the desired design. The use of the jacquard equipped loom eliminates the cumbersome process of freeing EL wire from the woven fabric by cutting on either side. The weaving is carried using a jacquard machine in a desired pattern as per the final product. Floats are kept in the design wherever access to EL wire is needed. This ensures easy access to EL wire ends for making further connection.
In alternative embodiments, the EL wire (200) may be powered from a piezo based system that lights the EL wire (200) whenever there is any motion in the garment due to user movement. The piezo based system may comprise of thin film piezo stitched on to substrate or piezo based substances coated or laminated on to the substrate. The power generated may either directly be delivered to the EL driver (201) after regulation or may be used to recharge the batteries supplying power to the EL wires (200). However, in case of garments, the EL driver (201) may be well hidden in a secret pocket or used as the garment accessory like button, buckle etc. Rechargeable battery may be charged using wireless charging system consisting of an antenna and suitable circuitry that is laminated on to the substrate and products made from such materials like garments, shoes, seating, home furnishing, protective clothing etc. Further, the multicolor EL may be used to obtain various design effects.
Examples
Hereinafter, the present invention will be described in more detail based on example. The example is not intended to limit the scope of the present invention. It is believed the invention will be better understood from the following detailed example:
In this one example, the fabric having 160 cm was woven. The weaving trial was taken on Dornier Rigid Rapier Loom machine wherein a plain weave was selected. 3/12 cotton OE was used as the warp and weft base yarn. The EL wire was having diameter between 0.8 – 0.9 mm. The warp tension was maintained at approximately 201 N. The EL wire was placed at every 1 inch in the weft direction. The fabric construction – EPI 42 – 44; PPI 20 – 22 having GSM of around 400.
The embodiments of the invention shown and discussed herein are merely illustrative of modes of application of the present invention. Reference to details in this discussion is not intended to limit the scope of the claims to these details, or to the figures used to illustrate the invention.
It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

,CLAIMS:
1. A method for integrating an electroluminescence (EL) wire with a fabric, the method comprising the steps of:
feeding an EL wire having a diameter ranging from 0.6 mm to 1 mm from an unwinding creel as a weft yarn;
maintaining creel tension of said EL wire in the range of 100 cN to 210 cN and beaming tension of said EL wire of about 20000 N; and
weaving said EL wire along with a plurality of warp yarns to form an EL wire integrated fabric having a portion of EL wire free at a seam of the fabric weave.

2. A method for manufacturing a garment from a fabric obtained by the method as claimed in claim 1, the method comprising the steps of:
cutting the EL wire integrated fabric of required size;
placing the free portion of the EL wire in a T connector such that an EL wire core is placed in an EL wire core contact point of the T-connector and an EL wire flexible strand placed in an EL wire flexible strand point of the T connector;
connecting wire connections of the EL wire core and the EL wire flexible strands to respective contact blades having respective push switches;
connecting connections of the contact blades to an EL wire driver through a power supply slots of the T connector; and
stitching the garment by positioning the T connector along with the EL driver in a seam of the fabric.
3. A garment manufactured by the method as claimed in claim 2.

4. A system for integrating an EL wire of the fabric, the system comprises:
at least one T-connector connecting the EL wire with an EL wire driver;
the T-connector having a housing, the housing including a power source supply slots and the EL wire contact portion configured on a surface thereof,
the EL wire contact portion including an EL wire flexible strand contact point that encloses an EL wire core contact point,
the EL wire connections extending from the EL wire flexible band contact point and the EL wire core contact point connecting to a plurality of contact blades positioned within the housing of the T connector, and
the contact blades having a push switches configured therewith.

5. The system as claimed in claim 4, wherein the EL wire core contact point receives EL wire core and the EL wire flexible strand contact point receives an EL wire flexible strand.

6. The system as claimed in claim 4, wherein the blade is a metal contactor.

7. The system as claimed in claim 4, wherein the EL wire driver is configured to communicate with a wireless communication device.

8. The system as claimed in claim 4, wherein the EL driver includes a programmed chip.

9. The system as claimed in claim 4, wherein the EL wire driver receives power through a power source that includes piezo based system or rechargeable batteries or AC power supply.