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Title:
FABRIC ARTICLE AND METHOD OF MAKING THE SAME
Document Type and Number:
WIPO Patent Application WO/2022/263828
Kind Code:
A1
Abstract:
The weft knitted fabric article (100) is knitted using a knitting machine comprising first and second needle beds. The fabric article comprises a base component comprising a first yarn and a second yarn having different properties. The base component comprises a first surface (102) and a second surface (104) opposing the first surface (102). In a first region (113) of the base component (101), knitted loops of the first yarn form the first surface (102) and knitted loops of the second yarn form the second surface (104). In a second region (115) of the base component (101), knitted loops of the second yarn form the first surface (102) and knitted loops of the first yarn form the second surface (104). The fabric article (100) further comprises a first conductive region (107, 109, 111) formed from conductive yarn and connected to the base component (101).

Inventors:
RIAZ NAEEM (GB)
Application Number:
PCT/GB2022/051517
Publication Date:
December 22, 2022
Filing Date:
June 15, 2022
Export Citation:
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Assignee:
PREVAYL INNOVATIONS LTD (GB)
International Classes:
D04B1/10; A61B5/00; A61B5/27; D04B1/12
Domestic Patent References:
WO2021214433A12021-10-28
Foreign References:
CN201842937U2011-05-25
EP3804614A12021-04-14
US20120144561A12012-06-14
US20120144561A12012-06-14
Other References:
DAVID J SPENCER: "Knitting technology", 2001, WOODHEAD PUBLISHING LIMITED
Attorney, Agent or Firm:
APPLEYARD LEES IP LLP (GB)
Download PDF:
Claims:
CLAIMS

1 . A method of weft knitting a fabric article using a knitting machine comprising first and second needle beds, the method comprising: knitting part of a base component using a first yarn having a first property and a second yarn having a second property different to the first property, the knitting comprising selectively switching between:

(a) using the first needle bed to form knitted loops using the first yarn and the second needle bed to form knitted loops using the second yarn; and (b) using the first needle bed to form knitted loops using the second yarn and the second needle bed to form knitted loops using the first yarn; and knitting conductive yarn to form a first conductive region connected to the part of the base component. 2. A method as claimed in claim 1 , wherein (a) comprises using the first needle bed to form knitted loops using the first yarn, the second needle bed to form tuck stitches using the first yarn, the second needle bed to form knitted loops using the second yarn, and the first needle bed to form tuck stitches using the second yarn. 3. A method as claimed in claim 1 or 2, wherein (b) comprises using the first needle bed to form knitted loops using the second yarn, the second needle bed to form tuck stitches using the second yarn, the second needle bed to form knitted loops using the first yarn, and the first needle bed to form tuck stitches using the first yarn. 4. A method as claimed in any preceding claim, wherein knitting the part of the base component comprises knitting one or more pairs of courses of yarn using tuck-rib stitches, wherein a first course in the pair of courses is knitted using the first yarn and a second course in the pair of courses is knitted using the second yarn. 5. A method as claimed in claim 4, wherein the first course comprises a first sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed, and a second sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed.

6. A method as claimed in claim 4 or 5, wherein the second course comprises a first sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed, and a second sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed.

7. A method as claimed in any of claims 4 to 6, wherein the second course comprises the reverse of the first course such that stitches performed on the first needle bed for the first course are performed on the second needle bed for the second course, and stitches performed on the second needle bed for the first course are performed on the first needle bed for the second course.

8. A method as claimed in any preceding claim, further comprising knitting a further part of the base component.

9. A method as claimed in claim 8, wherein knitting the further part of the base component comprises using the first yarn and the second yarn and comprises selectively switching between:

(a) using the first needle bed to form knitted loops using the first yarn and the second needle bed to form knitted loops using the second yarn; and

(b) using the first needle bed to form knitted loops using the second yarn and the second needle bed to form knitted loops using the first yarn.

10. A method as claimed in claim 9, wherein (a) comprises using the first needle bed to form knitted loops using the first yarn, the second needle bed to form tuck stitches using the first yarn, the second needle bed to form knitted loops using the second yarn, and the first needle bed to form tuck stitches using the second yarn.

11. A method as claimed in claim 9 or 10, wherein (b) comprises using the first needle bed to form knitted loops using the second yarn, the second needle bed to form tuck stitches using the second yarn, the second needle bed to form knitted loops using the first yarn, and the first needle bed to form tuck stitches using the first yarn.

12. A method as claimed in any of claims 9 to 11 , wherein knitting the further part of the base component comprises knitting one or more pairs of courses of yarn using tuck-rib stitches, wherein a first course in the pair of courses is knitted using the first yarn and a second course in the pair of courses is knitted using the second yarn.

13. A method as claimed in claim 12, wherein the first course comprises a first sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed, and a second sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed.

14. A method as claimed in claim 12 or 13, wherein the second course comprises a first sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed, and a second sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed.

15. A method as claimed in any of claims 12 to 14, wherein the second course comprises the reverse of the first course such that stitches performed on the first needle bed for the first course are performed on the second needle bed for the second course, and stitches performed on the second needle bed for the first course are performed on the first needle bed for the second course.

16. A method as claimed in any preceding claim, wherein the first yarn and the second yarn have different colours.

17. A method as claimed in any preceding claim, wherein the first yarn and the second yarn have different textures.

18. A method as claimed in any preceding claim, wherein knitting the conductive yarn to form the first conductive region comprises knitting a plurality of courses of conductive yarn using one of the first and second needle beds to form a raised conductive region that extends away from a surface of the base component.

19. A method as claimed in claim 18, further comprising knitting at least one course of filler yarn using tuck stitches such that the filler yarn is deposited within a space formed between the first conductive region and the base component.

20. A method as claimed in any preceding claim, further comprising knitting conductive yarn to form a second conductive region connected to the base component.

21 . A method as claimed in any claim 20, wherein the first conductive region is knitted using the second needle bed and the second conductive region is knitted using the first needle bed such that the first and second conductive regions are provided on opposing surfaces of the base component.

22. A method as claimed in any of claims 20 or 21 , further comprising knitting conductive yarn to form a third conductive region, the third conductive region connected to the base component.

23. A method as claimed in claim 22, wherein the second conductive region electrically connects the first conductive region to the third conductive region.

24. A computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine comprising a first needle bed and a second needle bed, are operable to cause the computer to control the knitting machine to perform the method as claimed in any preceding claim. 25. A weft knitted fabric article comprising: a base component comprising a first yarn and a second yarn having different properties, the base component comprising a first surface and a second surface opposing the first surface, and wherein, in a first region of the base component, knitted loops of the first yarn form the first surface and knitted loops of the second yarn form the second surface, and wherein, in a second region of the base component, knitted loops of the second yarn form the first surface and knitted loops of the first yarn form the second surface; and a first conductive region formed from conductive yarn and connected to the base component.

Description:
FABRIC ARTICLE AND METHOD OF MAKING THE SAME

The present invention is directed towards a fabric article and method of making the same. The present invention is directed, in particular, towards a fabric article comprising a fabric base component and conductive regions provided on the base component.

Background

Fabric articles comprising conductive regions such as in the form sensing components can be designed to interface with a wearer of the article to determine information such as the wearer's heart rate and rate of respiration. The sensing components may comprise electrodes and connection terminals electrically connected together via an electrically conductive pathway. An electronics module for processing and communication can be removably coupled to the connection terminals so as to receive the measurement signals from the electrodes. The fabric articles may be incorporated into or form a wearable article such as a garment.

It is desirable to form conductive regions from conductive yarn (electrically conductive yarn) that is knitted with a base fabric layer (base component) during a single knitting operation. This process simplifies the process of integrating electrodes into wearable articles and avoids the need for metallic or conductive polymer elements to be incorporated into a fabric. Conductive fabric electrodes are also comfortable to wear and can look, behave and feel like normal garment fabric.

Knitting conductive yarn is preferred over other techniques, such as weaving, as knitted structures are able to stretch without directly stretching the yarns used to form the knitted structure. Instead, when a knitted structure is stretched, the loops are deformed. This contrasts with woven articles where the yarns are directly stretched when the woven article is stretched. It will be appreciated that stretching a conductive yarn can change its electrical properties.

United States Patent Application Publication No. 2012/0144561 A1 discloses knitting techniques for forming three-dimensional textile electrodes. A conductive surface forming the electrode is knit using a back needle bed of a knitting machine while an isolating surface is knit using the front needle bed. A thread network is provided in a space formed between the conductive surface and the isolating surface using a tucking technique. It is desirable to overcome at least some of the problems associated with the prior art, whether explicitly discussed herein or otherwise. Summary

According to the present disclosure there is provided a fabric article and method of making the same as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the present disclosure, there is provided a method of weft knitting a fabric article using a knitting machine comprising first and second needle beds.

The method comprises knitting part of a base component using a first yarn having a first property and a second yarn having a second property different to the first property. The knitting comprising selectively switching between:

(a) using the first needle bed to form knitted loops using the first yarn and the second needle bed to form knitted loops using the second yarn; and

(b) using the first needle bed to form knitted loops using the second yarn and the second needle bed to form knitted loops using the first yarn.

The method further comprises knitting conductive yarn to form a first conductive region connected to the part of the base component.

The conductive yarn may be electrically conductive.

Advantageously, the base component is knitted using first and second yarns which have different properties. The knitting switches between using the front and back needle bed to form knitted loops using the first yarns and also switches between using the front and back needle bed to form knitted loops using the second yarns. This enables the position of the knitted loops of the first and second yarns to be controlled. The resultantly formed based component will have a first surface and a second surface opposing the first surface. In a first region of the base component, knitted loops of the first yarn form the first surface and knitted loops of the second yarn form the second surface. Meanwhile, in a second region of the base component, knitted loops of the of the second yarn form the first surface and knitted loops of the first yarn form the second surface. As the first and second yarns have different properties, this allows for the properties of the first and second surface of the base component to be varied.

In one example, the first and second yarns have different colours. The method according to the present disclosure allows for patterns, decorative elements, text or images to be formed as part of the process of knitting the base component. In some examples, the method enables the base component to form an information element that can indicate information such as the size, manufacturer or owner of the fabric article. As the information element is formed as part of the knitting process rather than being subsequently printed onto or stitched into the fabric article, the manufacturing process is simplified.

The term “first needle bed” may refer to the front bed or the back needle bed of a flat-bed knitting machine such as a V-bed knitting machine. The “second needle bed” may refer to the other of the front bed and the back needle bed of the flat-bed knitting machine.

The first and second yarns may both be non-conductive yarns. The different properties may be one or a combination of different materials, colours, textures, weights, and thickness. The properties are not limited to these examples.

(a) may comprise using the first needle bed to form knitted loops using the first yarn, the second needle bed to form tuck stitches using the first yarn, the second needle bed to form knitted loops using the second yarn, and the first needle bed to form tuck stitches using the second yarn.

(b) may comprise using the first needle bed to form knitted loops using the second yarn, the second needle bed to form tuck stitches using the second yarn, the second needle bed to form knitted loops using the first yarn, and the first needle bed to form tuck stitches using the first yarn.

Knitting part of the base component may comprise knitting one or more pairs of courses of yarn using tuck-rib stitches, wherein a first course in the pair of courses is knitted using the first yarn and a second course in the pair of courses is knitted using the second yarn.

The terminology commonly used in the fabric/textile/knitting trade to define a sequence of tuck stitches on one bed, complemented by knitted stitches on the opposing bed, is “Full Cardigan Stitch”.

The first course may comprise a first sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed, and a second sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed.

The second course may comprise a first sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed, and a second sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed.

The second course may comprise the reverse of the first course such that stitches performed on the first needle bed for the first course are performed on the second needle bed for the second course, and stitches performed on the second needle bed for the first course are performed on the first needle bed for the second course. Additional knitted sequences may be provided in addition to the first and second sequences referred to above. Any number of knitted sequences may be provided to form the desired effect in the base component.

The method may further comprise knitting a further part of the base component.

Knitting the further part of the base component may comprise using the first yarn and the second yarn and comprises selectively switching between: (a) using the first needle bed to form knitted loops using the first yarn and the second needle bed to form knitted loops using the second yarn; and (b) using the first needle bed to form knitted loops using the second yarn and the second needle bed to form knitted loops using the first yarn; and In relation to knitting the further part of the base component, (a) may comprise using the first needle bed to form knitted loops using the first yarn, the second needle bed to form tuck stitches using the first yarn, the second needle bed to form knitted loops using the second yarn, and the first needle bed to form tuck stitches using the second yarn. In relation to knitting the further part of the base component, (b) may comprise using the first needle bed to form knitted loops using the second yarn, the second needle bed to form tuck stitches using the second yarn, the second needle bed to form knitted loops using the first yarn, and the first needle bed to form tuck stitches using the first yarn. Knitting the further part of the base component may comprise knitting one or more pairs of courses of yarn using tuck-rib stitches, wherein a first course in the pair of courses is knitted using the first yarn and a second course in the pair of courses is knitted using the second yarn.

The first course may comprise a first sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed, and a second sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed.

The second course may comprise a first sequence of knitted loops on the first needle bed and tuck stitches on the second needle bed, and a second sequence of tuck stitches on the first needle bed and knitted loops on the second needle bed.

The second course may comprise the reverse of the first course such that stitches performed on the first needle bed for the first course are performed on the second needle bed for the second course, and stitches performed on the second needle bed for the first course are performed on the first needle bed for the second course.

The first yarn and the second yarn may have different colours.

The first yarn and the second yarn may have different textures.

Knitting the conductive yarn to form the first conductive region may comprise knitting a plurality of courses of conductive yarn using one of the first and second needle beds to form a raised conductive region that extends away from a surface of the base component.

The method may further comprise knitting at least one course of filler yarn using tuck stitches such that the filler yarn is deposited within a space formed between the first and/or second conductive region and the base component. The filler yarn may be knit using a combination of tuck and float-stitches. The filler yarn may be an expanding yarn.

The method may further comprise knitting conductive yarn to form a second conductive region connected to the base component.

The first conductive region may be knitted using the second needle bed and the second conductive region may be knitted using the first needle bed such that the first and second conductive regions are provided on opposing surfaces of the base component.

The method may further comprise knitting conductive yarn to form a third conductive region, the third conductive region connected to the base component.

The second conductive region may electrically connect the first conductive region to the third conductive region.

The base component and the conductive region may form a continuous body of weft knitted fabric.

Advantageously, the present disclosure provides a continuous body of knitted fabric that comprises conductive regions integrally formed with the base component. This simplifies the manufacturing process as the conductive regions and base component are manufactured during a single knitting operation. The fabric article structure simplifies the knitting techniques required to form the conductive regions integrally with the base component. That is, the fabric article structure facilitates the manufacture of the continuous body of fabric in a single knitting operation. The conductive regions may be a unitary knitted structured form from a single length of conductive yarn. This may mean that the first conductive region, second conductive region and optional third conductive region are formed from the same conductive yarn during a single knitting operation. This simplifies the manufacturing process and increases the comfort of the fabric article as elements such as wires and hardware connectors are not required.

The first conductive region may form an electrode for monitoring activity at a body surface. The fabric article may be a wearable article. The fabric article may be a garment.

The fabric article may be arranged to be integrated into a wearable article, optionally a garment. The fabric article may be arranged to be stitched, bonded or otherwise adhered to the wearable article. The fabric article may be integrally formed with the wearable article.

The knitting machine may be a flat bed knitting machine such as a V-bed flat knitting machine.

According to a second aspect of the disclosure, there is provided a computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine comprising a first needle bed and a second needle bed, are operable to cause the computer to control the knitting machine to perform the method according to the first aspect of the disclosure.

According to a third aspect of the disclosure, there is provided a weft knitted fabric article comprising: a base component comprising a first yarn and a second yarn having different properties, the base component comprising a first surface and a second surface opposing the first surface, and wherein, in a first region of the base component, knitted loops of the first yarn form the first surface and knitted loops of the second yarn form the second surface, and wherein, in a second region of the base component, knitted loops of the second yarn form the first surface and knitted loops of the first yarn form the second surface; and a first conductive region formed from conductive yarn and connected to the base component.

The fabric article may be manufactured according to the method of the first aspect of the disclosure.

Brief Description of the Drawings

Examples of the present disclosure will now be described with reference to the accompanying drawings, in which: Figure 1 is a simplified schematic side-on view of a V-bed knitting machine;

Figures 2 and 3 are knitting notation diagrams showing a method of knitting loops using the front bed or the back bed of a knitting machine;

Figures 4 and 5 show the front and back surfaces of a fabric article knitting according to the methods of Figures 2 and 3;

Figure 6 is a knitting notation diagram showing a method of knitting loops using both the front bed and the back bed of a knitting machine;

Figures 7 and 8 are knitting notation diagrams showing a method of knitting tuck-stitches using the front bed or the back bed of a knitting machine;

Figure 9 is a knitting notation diagram showing a method of knitting a combination of knitting loops and float stitches and a combination of tuck-stitches and float-stitches using the front and/or back bed of a knitting machine;

Figure 10 is a knitting notation diagram showing a method of knitting full-cardigan stitches using a knitting machine;

Figure 11 shows a fabric article made according to the method of Figure 10;

Figures 12A to 12B show front, side and back surfaces of an example fabric article;

Figure 13 shows a wearable article comprising the fabric article of Figures 12A to 12B;

Figure 14 shows an electronics module positioned on the wearable article of Figure 13;

Figures 15A and 15B show front and back surfaces of an example fabric article according to aspects of the present disclosure;

Figures 16A and 16B show front and back surfaces of an example base component of a fabric article according to aspects of the present disclosure; and

Figures 17A-17D are knitting notation diagrams showing an example method of knitting a fabric article according to aspects of the present disclosure.

Detailed Description

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the disclosure is provided for illustration purpose only and notforthe purpose of limiting the disclosure as defined by the appended claims and their equivalents.

It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

The present disclosure relates to fabric articles. The terms fabric and textile are used interchangeably and are not intended to convey different meanings. The fabric articles are knitted from yarns.

The fabric articles may form or be incorporated into a wearable article. “Wearable article” as referred to throughout the present disclosure may refer to any form of article which may be worn by a user such as a smart watch, necklace, bracelet, or glasses. The wearable article may be a garment. The garment may refer to an item of clothing or apparel. The garment may be a top. The top may be a shirt, t-shirt, blouse, sweater, jacket/coat, or vest. The garment may be a dress, brassiere, shorts, pants, arm or leg sleeve, vest, jacket/coat, glove, armband, underwear, headband, hat/cap, collar, wristband, stocking, sock, or shoe, athletic clothing, personal protective equipment, swimwear, wetsuit or drysuit

The garment may be a tight-fitting garment. Beneficially, a tight-fitting garment helps ensure that the sensor devices of the garment are held in contact with or in the proximity of a skin surface of the wearer. The garment may be a compression garment. The garment may be an athletic garment such as an elastomeric athletic garment.

The fabric articles may be constructed from natural fibres, synthetic fibres, or a natural fibre blended with one or more other materials which can be natural or synthetic. The yarn may be cotton. The cotton may be blended with polyester and/or viscose and/or polyamide according to the particular application. Silk may also be used as the natural fibre. Cellulose, wool, hemp and jute are also natural fibres that may be used in the wearable article. Polyester, polycotton, nylon and viscose are synthetic fibres that may be used in the wearable article.

The fabric articles according to the present disclosure comprise knitted fabric. This contrasts with other fabric constructions such as woven fabrics. Woven and knitted fabrics differ in the way yarns are interwoven or knotted together. A woven fabric is created by interweaving pretensioned lengths of yarn horizontally in between threads running vertically. These vertical, or warp threads, wrap themselves around the horizontal, or weft thread, after every course, and are themselves pre-tensioned. During the manufacture of a woven fabric, all of the yarns running in every direction must be pulled tight at all teams. If the yarns are not tight during knitting, the needles will snag on slacker yarns and break, causing mechanical damage.

Moreover, woven fabrics incorporating conductive yarn are potentially subjected to a change of resistance when stretched apart because, when stretching a woven fabric, the yarns and thus the conductive particles in the yarn will be stretched further apart. This property is undesirable for sensing operations such as for fabric-based sensing electrodes.

The present disclosure is directed towards knitted fabrics and, in particular, weft knitted fabrics. Weft knitted fabrics can be knit from a single yarn, but in aspects of the present disclosure multiple yarns are used so as to provide different regions of the fabric with different properties. In weft knitted fabrics, a weft thread is pulled through already formed loops of the same thread and, unlike warp knitting, is not required to be held taut or under stress from a warp thread. This construction allows for stitches (loops) in the fabric article to deform and alter their shape under stress without stretching the yarn itself. This helps maintain a constant level of electrical resistance.

Warp knitted fabrics are another form of knitted article and can be considered a hybrid between woven and knitted. They are formed using loops, but each column of loops is made from its own thread. Warp knitted threads may allow for more stretch than a woven fabric but are generally not as stretchy as weft knitted fabrics.

To aid in the understanding of the invention, a brief overview of knitting machines and the stitches that knitting machines can generate is provided below. This explanation is not intended to be a full disclosure of the common general knowledge of the skilled person, but instead is only provided to aid in the understanding of the invention.

Figure 1 shows simplified schematic diagrams of a conventional V-bed flat knitting machine 1 which is suitable for use in knitting the fabric articles described herein.

The knitting machine 1 comprises a front needle bed 3 and a back needle bed 5. The front and back needle beds 3, 5 diagonally approach once another at an angle generally between 90 degrees and 104 degrees to each other, giving an inverted V-shape appearance.

The front and back needle beds 3, 5 each comprise a large number of needles 7, 9. The needles are typically latch needles. Each needle 7,9 is able to create and manipulate individual stitches. The number of needles per inch is referred to as the gauge of the knitting machine 1 . Typically, knitting machines have a gauge of between 7 and 20. The needles 7, 9 are controlled by a needle cam 11 that traverses across the needle beds 3, 5 in both left-to-right and right-to-left directions. The needle cam 11 is designed to knit a course of loops on both the front bed and the back needle bed during a traverse in either the left or the right direction.

Yarn is fed to the needle beds 3, 5 by one or more yarn carriers (not shown). Multiple yarn carriers are typically used to allow for a variety of yarns to be introduced into the fabric article at desired locations.

Figure 2 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the front needle bed 3 of the knitting machine 1 .

The diagram comprises several rows of dots where each dot represents a needle on either the front needle bed 3 or the back needle bed 5.

The rows are grouped into pairs. In each pair, one row represents needles on the front needle bed 3 and the other row represents needles on the back needle bed 5. Each pair of dots show the knitting operations performed to form a knitted course of the fabric article.

The type of knitting operation performed is represented by the lines that traverse along the dots. Here, the knitting operations are knitted loops as indicated by the lines looping around the dots representing needles on the front needle bed 3. The diagram is read from bottom to top. This means that the knitting operations S1 are performed first followed by S2, S3, S4, S5 and S6 in order. Each of the knitting operations S1- S6 involve forming knitted loops using the front needle bed 3 only. The back needle bed 5 is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

Figure 3 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the back needle bed 5 of the knitting machine 1. Each of the knitting operations S11-S16 involve forming knitted loops using back needle bed 5 only. The front needle bed 3 is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

Figures 4 and 5 show a knitted fabric article 20 that may be formed as a result of front-bed only knitting using the techniques shown in Figure 2 or back-bed only knitting using the techniques shown in Figure 3. The knitted fabric article 20 is a single-faced structure as only one of the needle beds 3, 5 is used to form the knitted loops. Figure 4 shows the face 21 of the fabric article 20 and Figure 5 shows the back 23 of the fabric article 2.

Figure 6 shows an example knitting notation diagram in which a plurality of courses of knitting loops are formed using both the front and back needle beds 3, 5. Each of the knitting operations S21-S27 involve forming knitted loops using both the front and the back needle bed 3, 5. This can be referred as double-knitting. The resultantly formed knitted article comprises a number of courses of knitted loops and has a double-faced structure as compared to the single-faced structure of the fabric article formed using the operations shown in Figures 2 and 3.

Figures 7 and 8 show example knitting notation diagram in which a plurality of courses (S31- S36 and S41-S47) of tuck stitches are formed using the front needle bed 3 only (Figure 7) or using the back needle bed 5 only (Figure 8). Tuck stitches are produced when a needle holding an existing loop also receives a new loop which rather than being intermeshed through the existing loop is tucked in behind the existing loop on the reverse side of the stitch. Tuck stitches are represented in the diagram by as a “V” (or inverted “V”) shape that goes around the needle that performs the tuck stitch.

Figure 9 is an example knitting notation diagram in which float stitches are interspersed between other needle stitches. Float stitches are produced when a needle misses the yarn which instead floats over to the next chosen needle. Floats are represented in the needle diagram as a bypassed point.

Knitting operation S51 involves a series of knitted loops on the front needle bed (3) with float stitches in between. In other words, every other needle on the front needle bed (3) is used to knit a loop.

Knitting operation S52 involves a series of knitted loops on the back needle bed (5) with float stitches in between,

Knitting operation S53 involves a series of tuck stitches on the back needle bed (5) with float stitches in between.

Knitting operation S54 involves a series of tuck stitches on the front needle bed (3) with float stitches in between.

Knitting operation S55 involves a series of tuck stitches alternatingly performed on the front needle bed (3) and the back needle bed (5) with float stitches in between. Tuck-rib stitches are another form of knit structure formed by using knitted loops on one needle bed and tuck-stitches on the other needle bed. Tuck-rib stitches can be used in full-cardigan stitches.

Figure 10 is an example knitting notation diagram which shows a series of full-cardigan stitches. Full-cardigan stitches use repeating pairs of knit courses where the second course in each pair uses the reverse of the stitches used for the first course in each pair. The first and second courses both use tuck stitches on one needle bed and knitted loops on the other needle bed.

The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border. Tuck loops can increase the fabric thickness and make it heavier in weight and bulkier in handle.

The knitting operation S61 is a sequence of knitted loops on the front bed and tuck stitches on the back bed. The knitting operation S62 is the reverse of the sequence of S61 and has tuck stitches on the front bed and knitted loops on the back bed. Operations S63-S66 are a repetition of the sequences S61 and S62.

Figure 11 shows a knitted fabric article 30 formed as a result of the knitting operations of Figure 10. The full-cardigan stitches result in a balanced 1 x 1 tuck-rib structure with the same appearance when viewed from both faces of the fabric. This drawing is obtained from the textbook: Knitting technology (2001) David J Spencer, Third edition, Woodhead Publishing Limited, Cambridge, UK (Figure 18.6, page 219).

Referring to Figures 12A-12C there is shown an example fabric article 40.

The fabric article 40 comprises a base component 41 having a first surface 42 and a second surface 43 that opposes the first surface 42. The base component 41 has a pair of straight- edged end regions 44, 45. The base component 41 has an approximate rectangular shape. The base component 41 is formed from a non-conductive yarn.

A plurality of conductive regions 46, 47, 48 are provided on the base component 41 .

The first conductive region 46 is attached to the second surface 43 of the base component 41 and is provided proximate to the end region 44.

The second conductive region 47 is attached to the first surface 42 of the base component 41 and extends across part of the base component 41 to the end region 45. The conductive region 47 forms an electrode. The third conductive region 48 is attached to the second surface 43 of the base component 41 . The conductive region 48 extends along the second surface 43 in the length direction of the base component 41 and electrically connects the first conductive region 46 to the second conductive region 47.

Referring to Figure 13, there is shown an assembly 50 comprising a fabric layer 51 and two of the fabric articles 40 shown in Figures 12A-12C. The assembly 50 forms a wearable article such as a garment. The first surfaces 42 of the fabric articles 40 are attached to the fabric layer 51 .

The two fabric articles 40 are arranged such that the end regions 44 are located adjacent to one another. The end regions 44 may abut one another or there may be a small gap between the end regions. This arrangement means that the first conductive regions 46 are located proximate to one another.

Referring to Figure 14, there is shown a removeable electronics module 300 positioned on the assembly/article 500.

The electronics module 300 comprises a housing 301 . A pair of electrical contacts 311 are provided on the lower surface 303 of the housing 301. The contacts 311 are electrically coupled to a controller 309 disposed within the housing 301 .

When positioned on the wearable assembly 50, the contacts 311 are brought into physical contact with the connection regions 46 of the fabric articles 40. In this way, a temporary electrical connection is formed between the controller 309 of the electronics module 300 and the electrodes 47 of the fabric article 100. The electrodes 47 are able to contact a skin surface when the wearable article is worn so as to measure signals from the skin surface and/or apply signals to the skin surface. Providing the electrodes 47 and the connection regions 46 on opposing surfaces enables the electronics module 300 to be connected to the electrode 47 from an outer surface which faces away from the skin surface when worn without additional modification to the fabric articles 40.

The wearable article 50 may further comprise a holder for temporarily retaining the electronics module 300 and holding the electronics module 300 in contact with the connection regions 46. The holder may, for example, be a pocket integrally knit with the base component 41 of the fabric article 40 or a separate layer of the wearable article (e.g. fabric layer 51). The pocket may have an opening which enables access inside the pocket. The electronics module 300 may be inserted into and removed from the pocket. When positioned in the pocket, the contacts 311 are brought into conductive connection with the connection regions 46. The electronics module 300 is further arranged to wirelessly communicate data to a mobile device when coupled to the wearable article. Various protocols enable wireless communication between the electronics module 300 and the mobile device Example communication protocols include Bluetooth ®, Bluetooth ® Low Energy, and near-field communication (NFC).

The fabric layer 51 is positioned proximate to skin surface S of wearer such that the electrodes 47 are able to brought into contact with the skin surface S. The fabric layer 51 may comprise openings to expose the electrodes 47.

Figures 15A-15B show a fabric article 100 according to aspects of the present disclosure. The fabric article 100 is similar to the fabric article 40 shown in Figures 12A- 12C but uses a different construction of the base component 41/101 to allow for the properties of the base component 101 to be varied.

The fabric article 100 is an elongate and narrow strip of material. The fabric article 100 is able to be worn so as to obtain measurement signals from the wearer. The fabric article 100 may be used to form a chest strap or wrist strap or may be integrated into a separate wearable article such as a garment. The fabric article 100 may be adhesively bonded to an inner surface of a garment for example such as by using an adhesive film.

The fabric article 100 comprises a continuous body of fabric 100. Here, continuous body of fabric 100, refers to a unitary fabric structure that is integrally knit. This means that seams are not provided between different sections of the fabric article 100. In other words, the fabric article is seamless. Although the fabric is seamless, different types of yarns such as conductive and non- conductive yarns are provided in the continuous body of fabric 100.

The fabric article 100 comprises a base component 101 . The fabric article 100 has a generally rectangular shape with two end regions 103, 105.

The base component 101 is knit by knitting courses of yarn. The courses extend in the X- direction. The courses extend along the length of the base component 101 from the end region 103 to the end region 105.

The base component 101 has a first surface 102 and a second surface 104 opposing the first surface 102. The first surface 102 and the second surface 104 are parallel to one another and spaced apart along the Z axis. In use, the first surface 102 faces towards the skin surface of the wearer of the fabric article 100 and the second surface 104 faces away from the skin surface of the wearer.

The fabric article 100 further comprises three conductive regions 107, 109, 111. The three conductive regions 107, 109, 111 form a sensing component for the fabric article 100.

The sensing component is part of the continuous body of fabric. This means that the sensing component is integrally formed with the base component 101 . The sensing component is formed from conductive yarn, and in particularly is a unitary knitted structure formed from a single length of conductive yarn. This means that separate wires, connectors or other hardware elements are not required to electrically connect the different parts of the sensing component together.

The first conductive region 107 extends along the first surface 102 of the base component 101 and is provided proximate to the end region 105. The second conductive region 109 extends along the second surface 104 of the base component 101. The third conductive region 111 extends along the second surface 104 of the base component 101 and is provided proximate to the end region 103.

The first conductive region 107 forms an electrode 107 for monitoring activity at a body surface.

The first conductive region 107 is a three-dimensional conductive region 107 that extends away from the first surface 102 along the Z-axis as shown in Figure 12B. This three-dimensional/raised conductive region 107 forms a three-dimensional/raised electrode 107 for contacting the skin surface of the wearer to measure signals from the wearer and/or introduce signals into the wearer. The first conductive region 107 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the first surface 102 of the base component 101 . The remaining courses of conductive yarn extend away from the first surface 102 of the base component 101 to form the raised conductive region 107.

The electrode 107 may be arranged to measure one or more biosignals of a user wearing the fabric article 100. Here, “biosignal” may refer to any signal in a living being that can be measured and monitored. The electrode 107 is generally for performing bioelectrical or bioimpedance measurements. Bioelectrical measurements include electrocardiograms (ECG), electrogastrograms (EGG), electroencephalograms (EEG), and electromyography (EMG). Bioimpedance measurements include plethysmography (e.g., for respiration), body composition (e.g., hydration, fat, etc.), and electroimpedance tomography (EIT). The electrode 107 may additionally or separately be used to apply an electrical signal to the wearer. This may be used in medical treatment or therapy applications. The third conductive region 111 forms a connection region 111 for electrically connecting with a removable electronics module 300 (Figure 14). In particular, a conductive interface element 311 of the electronics module 300 is able to contact the connection region 111 to electrically connect the electronics module 300 to the connection region 111.

The third conductive region 111 is a three-dimensional conductive region 111 that extends away from the second surface 104 along the Z axis as shown in Figure 12B. The third conductive region 111 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the second surface 104 of the base component 101. The remaining courses of conductive yarn extend away from the second surface 104 of the base component 101 to form the raised conductive region 107.

The second conductive region 109 forms a conductive pathway 109 that electrically connects the first conductive region 107 to the third conductive region 111. The conductive pathway 109 is substantially flush with (or extends to a lesser extent than the first or third conductive regions 107, 111) the second surface 104 of the base component 101 (Figure 12B) and is formed from one or more (two in this example) of courses of conductive yarn extending between adjacent courses of non-conductive yarn in the base component 101. Proximate to the first conductive region 107, part of the conductive yarn extends through the base component 101 so as to be electrically connected to the first conductive region 107 provided on the first surface 102. The first conductive region 107 and the third conductive region 111 are spaced apart from one another along the length of the fabric article 100. That is, they are spaced apart along the X-axis (Figures 15A and 15B).

The fabric article 100 can be manufactured integrally in a single knitting operation is therefore provided. This means that discrete electronic components do not need to be integrated into an already formed base component but instead the sensing component is formed of conductive yarn as the base component is being knitted. The resultant fabric article has a singular fabric structure which handles, feels, behaves and looks like a fabric while providing the desired sensing functionality.

The construction of fabric article 100 in Figures 15A to 15B provides the electrode 107 and connection region 111 on opposed surfaces 102, 104 of the base component 101. This is not required in all examples of the present disclosure as, in some examples, the electrode 107 and the connection region 111 may be provided on the same surface of the base component 101. The conductive regions 107, 109, 111 further comprise a filler material disposed therein. The filler material is integral with the continuous body of fabric and in particular comprises an expanding yarn. During the knitting operation for forming the continuous body of fabric, the expanding yarn is intruded into the conductive regions 107, 109, 111.

Beneficially, the filler material raises the profile of the conductive regions 107, 111 away from the base component 101. This helps to increase the quality, consistency and area of contact area. This is particularly beneficial for the raised electrode 107 as it helps ensure contact against the skin surface without requiring the fabric article 100 to provide additional compression such as through additional elastomeric material. The filler material maintains the shape of the raised conductive regions 107,111 and protects against deformation, buckle and roll even when they are rubbed against the skin or other surface. Moreover, using an expanding yarn means that the process of filling out the conductive regions 107, 111 is an intrinsic part of the manufacturing process. A separate manual process of inserting filler material into already formed conductive regions 107, 111 is not required.

The base component 101 in this example is formed from a first yarn and a second yarn having different properties. In this example, the different properties are colours. The first yarn has a first colour and the second yarn has a second colour different to the first colour. Other properties of the yarns such as texture, material, weight and thickness may additionally or separately be varied.

The first and second yarns are knitted to introduce colour variations in the first surface 102 and the second surface 104 of the base component 101.

In this example, the first yarn is white and the second yarn is black. For the majority of the base component 101 represented by region 113 in the drawings, the first and second yarns are knitted such that the knitted loops for the first yarn form the first surface 102 and the knitted loops for the second yarn form the second surface 104. In these regions, the first yarn is responsible for the appearance of the first surface 102 and the second yarn is responsible for the appearance of the second surface 104. This results in the base component 101 having a generally white first surface 102 and a generally black second surface 104. In one region 115, the knitted sequences are alternated such that knitted loops for the first yarn form the second surface 104 and knitted loops for the second yarn form the first surface 102. This results in a region 115 of the first surface 102 which is black and a region 115 of the second surface 104 which is white. In this example, this region 115 forms an information element for providing information about the fabric article 100. This information could include an owner of the fabric article, a length of the fabric article, a manufacturer of the fabric article or any other form of information as desired by the skilled person. The information element in this example is in the form of text but could equally be an image or a machine-readable code.

Beneficially, the information element is formed as a result of the knitting of the base component 101 using the first and second yarns. This means that the information element is integrally formed as part of the knitting process. A separate process such a printing, transferring, or stitching is therefore not required to form the information element. This simplifies the manufacturing process for forming the fabric article 100.

It will be appreciated that multiple different regions 115 could be formed in the base component 101 as desired by the skilled person.

Figures 16A and 16B show a simplified diagram of the example base component 101 of Figures 15A and 15B. The conductive regions are omitted from these drawings. Figure 16A shows the second surface 104 of the base component 101 which comprises a first region 113 formed by knitted loops of the second yarn and is represented by diagonal lines in the drawing. The second surface 104 of the base component 101 further comprises a second region 115 formed by knitted loops of the first yarn which is represented by horizontal lines in the drawing. Figure 16B shows the first surface 102 of the base component 101 which comprises a first region 113 formed by knitted loops of the first yarn which is represented by horizontal lines in the drawing. The first surface 102 of the base component 101 further comprises a second region 115 formed by knitted loops of the second yarn which is represented by diagonal lines in the drawing.

The base component 101 in the example of Figures 15A to 16B use tuck-rib stitches. The stitches may be knitted in a two-course repeat manner. The tuck-rib stitches are often referred to as full-cardigan stitches.

The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border this results in larger gaps between the stitches. The tuck stitches are not easily visible when viewing the first surface 102 or the second surface 104 of the base component 101.

Advantageously, knitting the base component 101 using cardigan stitches means that the base component 101 has larger gaps between stitches as compared to other knitting techniques such as just using knitted loops on both needle beds or an interlock knitting technique. These larger gaps enable the base component 101 to accommodate thicker conductive yarn. Thicker conductive yarn is advantageous as it is less likely to break and is more resistant to washing. Fabric articles with thicker conductive yarn can typically be washed a greater number of times without the measured impedance increasing beyond and acceptable value.

Yarn thickness may be measured using its yarn count. Yarn count is a measure of the total length per weight of yarn. The yarn count measures include Cotton Count (cc) which gives a measure of the number of 840 yard units in a pound of yarn, Worsted Count (wc) which gives a measure of the number of 560 yard units in a pound of yarn, and Numero Metric Count (nm) which gives a measure of the number of 1000 metre units in a kilogram of yarn.

Yarn counts are typically represented in the form X/Y, where X is the yarn count for a single ply of yarn and Y is the number of piles that make up the yarn. The number X is divided by Yto give the final yarn count.

For example, a yarn may have a yarn count of 30/2 nm which means that each ply has a yarn count of 30 and that there are two plies that make up the yarn. The final yarn count is 15 nm which means that there are 15000 metres of yarn per kilogram.

Another yarn may have a yarn count of 20/2 nm which means that each ply has a yarn count of 20 and that there are two plies that make up the yarn. The final yarn count is 10 nm which means that there are 10000 metres of yarn per kilogram.

A yarn with a lower yarn count in nm is therefore heavier per unit length and thicker than a yarn with a higher yarn count.

In some examples, a yarn with a yarn count of 15nm or higher is thin enough that it can fit through the gaps in a base component regardless of the knitting technique used to manufacture the base component, e.g. knit using both needle beds simultaneously or using an interlock technique. However, yarns with yarn counts lower than this value may be more challenging to fit through the gaps between stitches in the base component. This can increase the complexity of the knitting process and reduce the appearance and performance of the resultantly formed fabric article.

Advantageously, knitting the base component 101 using cardigan stitches results in larger gaps between the knitted stitches which allows for conductive yarns with a yarn count of less than 15nm to be intermeshed with the base component.

Moreover, using cardigan stitches result in a base component 101 with a reduced weight as cardigan stitches use less yarn and are lighter than other knit structures. This enables a wider base component 101 to be knitted for the same weight/amount of yam. Moreover, the knitting process for forming a base component 101 using cardigan stitches is faster than other knitting techniques such as interlock which enables the fabric article 100 to be manufactured more quickly. Therefore, forming the base component using cardigan stitches reduces the time required to knit the fabric article.

In preferred examples, the base component 101 is knit using cardigan stitches and the conductive yarn has a yarn count of less than 15nm. The yarn count may be less than 14nm, less than 13nm, less than 12nm, less than 11 nm. The yarn count may be greater than 5nm, greaterthan 6nm, greaterthan 7nm, greaterthan 8nm, orgreaterthan 9nm. The yarn count may be between 8nm and 12nm and is preferably 10 nm (e.g. a yarn with a yarn count of 20/2 nm). The conductive yarn in this example is preferably a stainless-steel yarn.

The present disclosure does not require that the base component 101 is knit using full-cardigan stitches or more generally tuck-rib stitches. Other knitting stitches may be used which enable knitted loops of yarn to switch between the surfaces 102, 104 of the fabric article 100.

Figures 17A to 17D show an example knitting operation for forming a fabric article in accordance with aspects of the present disclosure.

Figure 17A shows knitting operations S91-S96 used to knit part of a base component using the first and second yarns. The first yarn is represented by a solid black line in the drawings and the second yarn is represented by a dashed/broken black line. This first and second yarns are held on separate yarn carriers.

The knitting comprises knitting a plurality of pairs of courses (S91 , S92), (S93, S94), (S95, S96) of the first and second yarns using tuck-rib stitches.

In this example, the first and second yarns are non-conductive yarns and in particular, composite fabric elastomeric yarns having different colours. The yarns used in this example are composite fabric elastomeric yarn comprising 81% nylon and 19% elastane and are dyed to have their different colours. Of course, other non-conductive yarns may be used as desired by the skilled person. The non-conductive base component may comprise additional yarns which may be incorporated during the knitting of the base component. Moreover, it is not required that the different property of the first and second yarns is, or is limited to, their colour. The first and second yarns may be different types of yarn and may have other different properties such as different textures. Each pair comprises a first course (S91 , S93, S95) that uses the first yarn. The knitted courses (S91 , S93, S95) comprise different sequences of stitches that switch between using the front needle bed 3 and the back needle bed 5 to form the knitted loops.

When viewed from left to right, the course S91 starts by forming knitted loops on the front needle bed 3 and tuck stitches on the back needle bed 5. It will be appreciated that this means that the first yarn will be visible from the surface of the base component 101 formed by the front needle bed 3 but not visible from the surface of the base component 101 formed by the back needle bed 5. The course S91 then switches to forming tuck stitches on the front needle bed 3 and knitted loops on the back needle bed 5. It will be appreciated that this means that the first yarn will not be visible from the surface of the base component 101 formed by the front needle bed 3 but will be visible from the surface of the base component 101 formed by the back needle bed 5. The course S91 then switches back to forming knitted loops on the front needle bed 3 and tuck stitches on the back needle bed 5 before again forming tuck stitches on the front needle bed 3 and knitted loops on the back needle bed 5.

The other courses S93, S95 form similar sequences but are not required to be the same. It will be appreciated that the sequences will be varied as appropriate to form the desired pattern on the different surfaces of the base component 101 .

Each pair also comprises a second course (S92, S94, S96) that uses the second yarn. The second courses (S92, S94, S96) use the reverse of the sequence used to form the first course of their respective pair. This means, for example, that knitted loops formed on the front needle bed 3 during course S91 are formed on the back needle bed 5 during course S92 while knitted loops formed on the back needle bed 5 during course S91 are formed on the front needle bed 3 during course S92.

Step S97 comprises knitting a course of non-conductive yarn (e.g. the first or the second yarn) using both front and back needle beds without racking to balance out the tuck-rib structure.

Figures 17B and 17C show knitting operations S98-S111 used to form conductive regions 107, 109, 111 that are attached to the base component. The conductive yarn is held on a different yarn carrier to yarn carriers used for the first and second yarns.

The conductive yarn may be a stainless-steel yarn such as those manufactured by TIBTECH Innovations. The conductive yarn may be a silver coated yarn such as the Circuitex ™ conductive yarn from Noble Biomaterials Limited. Of course, other conductive yarns may be used. The conductive yarn may comprise a non-conductive or less conductive base yarn which is coated or embedded with conductive material such as carbon, copper and silver. S98-S100 comprise knitting three courses of conductive yarn using knitted loops on the back needle bed 5 only to form part of the first conductive region 107. The course knitted in step S98 is intermeshed with the previous course of non-conductive yarn used to form the base component 101 such that the first conductive region 107 is attached to the base component 101.

The additional courses knit in S99 and S100 are performed using the back needle bed 5 only and because of this, the opposite needles on the front needle bed 3, which are not used for knitting, are not able to balance out the knit layers. This causes the conductive yarn to bunch- up on the back-needle bed. This forms a three-dimensional structure in the finished fabric article 100. This three-dimensional structure may form an elongate tubular shape.

The number of courses is not required to be three and can instead be any number greater than or equal to one. Even with a limited number of courses, the 3D profile of the conductive region can still be provided by introducing the filler yarn as explained below.

S101 comprises knitting a course of conductive yarn comprising a sequence of knitted loops on the back needle bed 5 and a sequence of knitted loops on the front needle bed 3. The knitted loops on the back needle bed 5 continue the knitted of the first conductive region 107. The knitting on the front needle bed 3 forms part of the second conductive region 109 and the third conductive region 111. In effect, the transition from knitting on the back needle bed 5 to the front needle bed 3 pulls the conductive yarn through the base component 101. S102-S103 comprise knitting two courses of conductive yarn using knitted loops on the front needle bed 3 only. This continues the formation of the third conductive region 111. Because the conductive yarn is knitted using the front needle bed 3 only, the back needle bed 5 is not able to balance out the knit layers. This causes the conductive yarn to bunch-up to create a three- dimensional structure. This three-dimensional structure may form an elongate tubular shape.

Step S104 and S015 comprise knitting courses of filler yarn using tuck stitches separated by float stitches. The course of filler yarn comprises a sequence of tucks and floats on the front needle bed 3 and a sequence of tucks and floats on the back needle bed 5. Tuck knitting operations result in the formation of an extra stitch behind an existing stitch. The extra stitch is not visible from the outside surface of the fabric article. The tuck stitch is used to layer-in the filler yarn behind the conductive regions so that it is not visible from the outside of the fabric article. The filler yarn in this example is an expanding yarn. The expanding yarn may refer to a yarn that expands under the application of an external stimulus such as heat, pressure or steam. Preferably the yarn expands under the application of steam. The expanding yarn may comprise a polyester material and may be a polyester filament yarn. The expanding yarn used in this example is a Newlife ™ polyester filament yarn manufactured by Sinterama S.p.A.

Beneficially, the use of an expanding yarn means that after the fabric article is constructed, steam (for example) may be applied to cause the yarn to expand and bulk out the shape of the conductive regions 107, 109, 111 and provide further stability. It is particularly desired to bulk out the first and third conductive regions 107 and 111. The second conductive region 109 is bulked out to a lesser extent due to the fewer number of knit courses used to make the second conductive region 109.

As the expanding yarn expands to fill the space between the conductive regions 107, 109, 111 and the base component 101 , the space between the conductive regions 107, 109, 111 and the base component 101 does not need to be densely packed with filler material during the knitting operation. Less yarn is required than if a non-expanding filler material were used. For example, a single strand of expanding yarn may provide the necessary support and stability function when the steam (for example) is applied.

The filler yarn provides a stabilising function for the conductive regions 107, 109, 111 in order to reduce noise and other electronic artefacts. The filer yarn urges the profile of the conductive regions 107, 109, 111 out from the base component 101 and increase the quality, consistency and area of contact for the electrode 107 against the skin surface and the connection region 111 against the electronics module 300. This is provided without requiring an increase in the amount of compression applied to the skin surface by the fabric article 100. Moreover, as the expanding yarn is integrally knit with the remainder of the fabric article 100, this simplifies the manufacturing process and avoids the need to separately insert filler material afterthe continuous body of fabric is formed.

The filler yarn is knit using front needle bed 3 knitting in regions where the conductive yarn is knit using the back needle bed 5 (the first conductive region 107). The filler yarn is knit using back needle bed 5 knitting in regions where the conductive yarn is knit using the front needle bed 3 (the second and third conductive regions 109, 111). This is performed so as to anchorthe filler yarn on the base component 101 rather than the conductive regions 107, 109, 111. This is particularly desirable when an expanding yarn is used as a filler yarn as it helps ensure that the expanding yarn pushes against and urges the conductive regions 107, 109, 111 away from the base component 101 to form the desired three-dimensional shapes. Steps S106 and S107 comprise knitting further courses of the third conductive region 111 using the front needle bed 3.

Step S108 comprises knitting the final course of the third conductive region 111 and the second conductive region 109 using the front needle bed 3 and a further course of the first conductive region 107 using the back needle bed 5.

Steps S109-S111 comprise knitting the final courses of the first conductive region 107 using the back needle bed 5 only.

Figure 17D shows knitting operations S112-S118 used to knit a further part of the base component using the first and second yarns.

Step S112 comprises knitting a course of non-conductive yarn (e.g. the first or the second yarn) using both front and back needle beds to close off the conductive yarn regions knit in steps S98 to S111 .

Steps S113-S118 comprise knitting a plurality of pairs of courses (S 113, S 114), (S115, S 116), (S117, S118) of first and second yarn using tuck-rib stitches. The knitting operations are the same as described above in relation to steps S91 to S96. The precise sequence of knitted loops on the front and back needle beds 3, 5 may be varied as desired to form the desired patterns.

It will be appreciated that the above diagram is only a simplified example of knitting operations that may be performed according to aspects of the present disclosure.

The number of courses of yarn used to knit the base component 101 may be varied as appropriate by the skilled person so as to vary the width of the base component 101 in the finished fabric article 100. More or fewer knit courses may be provided.

Additional yarns may be used in knitting the base component if desired. Other example yarns include elastomeric yarns to add further stretch to the base component.

Moreover, additional stitches other than tuck-rib stitches may be used for the base component 101. For example, in addition to the tuck-rib stitches and double-knit stitches shown in the diagram other courses may be knit using techniques such as interlocking to impart additional desired properties for the base component 101.

The first, second, and third conductive regions 107, 109, 111 are not required to have the number of stitches or courses shown in the Figures. A greater number of courses can be knit to increase the three-dimensional effect of any or all of the conductive regions 107, 109, 111 . Fewer courses can also be knit to reduce the three-dimensional effect of any or all of the conductive regions 107, 109, 111.

The filler yarn while beneficial for enhancing the 3D effect of the conductive regions 107, 109, 111 is not required in all examples. The filler yarn may be omitted from any or all of the conductive regions 107, 109, 111.

The first conductive regions 107 is not required to be knit using the back needle bed 5 and could be knit using the front needle bed 3.

The second conductive region 109 is not required to be knit using the front needle bed 3 and could be knit using the back needle bed 5.

The third conductive region 111 is not required to be knit using the front needle bed 3 and could be knit using the back needle bed 5.

The first and second conductive regions 107, 109 could be knit using the back needle bed 5 while the third conductive region 111 could be knit using the front needle bed 3 or vice versa.

The first and third conductive regions 107, 111 could be knit using the back needle bed 5 while the second conductive region 109 could be knit using the front needle bed 3 or vice versa.

The first, second and third conductive regions 107, 109, 111 could all be knit using the front needle bed 3 or the back needle bed 5.

The knitting of the conductive regions 107, 109, 111 is not required to only use knitted loops as shown in the Figures additional stitches such as float stitches may be used if desired.

The present disclosure is not limited to electronics modules 300 (Figure 14) that communicate with mobile devices and instead may communicate with any electronic device capable of communicating directly with the electronics module 300 or indirectly via a server over a wired or wireless communication network. The electronic device may be a wireless device or a wired device. The wireless/wired device may be a mobile phone, tablet computer, gaming system, MP3 player, point-of-sale device, or wearable device such as a smart watch. A wireless device is intended to encompass any compatible mobile technology computing device that connects to a wireless communication network, such as mobile phones, mobile equipment, mobile stations, user equipment, cellular phones, smartphones, handsets or the like, wireless dongles or other mobile computing devices. The wireless communication network is intended to encompass any type of wireless network such as mobile/cellular networks used to provide mobile phone services.

The present disclosure is not limited to the use of pockets for releasably mechanically coupling the electronics module 300 to the wearable article/assembly and other mounting arrangements for the electronics module 300 are within the scope of the present disclosure. The mechanical coupling of the electronic module 300 to the wearable article may be provided by a mechanical interface such as a clip, a plug and socket arrangement, etc. The mechanical coupling or mechanical interface may be configured to maintain the electronic module 300 in a particular orientation with respect to the wearable article when the electronic module 300 is coupled to the wearable article. This may be beneficial in ensuring that the electronic module 300 is securely held in place with respect to the wearable article and/or that any electronic coupling of the electronic module 300 and the wearable article (or a component of the wearable article) can be optimized. The mechanical coupling may be maintained using friction or using a positively engaging mechanism, for example.

Beneficially, the removable electronic module 300 may contain all of the components required for data transmission and processing such that the wearable article only comprises the sensing components. In this way, manufacture of the wearable article may be simplified. In addition, it may be easier to clean a wearable article which has fewer electronic components attached thereto or incorporated therein. Furthermore, the removable electronic module 300 may be easier to maintain and/or troubleshoot than embedded electronics. The electronic module 300 may comprise flexible electronics such as a flexible printed circuit (FPC). The electronic module 300 may be configured to be electrically coupled to the wearable article.

It may be desirable to avoid direct contact of the electronic module 300 with the wearer’s skin while the wearable article is being worn. It may be desirable to avoid the electronic module 300 coming into contact with sweat or moisture on the wearer’s skin. The electronic module 300 may be provided with a waterproof coating or waterproof casing. For example, the electronic module 300 may be provided with a silicone casing.

The electronics module 300 may further comprise a power source (not shown). The power source is coupled to the controller 309 and is arranged to supply power to the controller 309. The power source may comprise a plurality of power sources. The power source may be a battery. The battery may be a rechargeable battery. The battery may be a rechargeable battery adapted to be charged wirelessly such as by inductive charging. The power source may comprise an energy harvesting device. The energy harvesting device may be configured to generate electric power signals in response to kinetic events such as kinetic events performed by a wearer of the garment. The kinetic event could include walking, running, exercising or respiration of the wearer. The energy harvesting material may comprise a piezoelectric material which generates electricity in response to mechanical deformation of the converter. The energy harvesting device may harvest energy from body heat of a wearer of the garment. The energy harvesting device may be a thermoelectric energy harvesting device. The power source may be a super capacitor, or an energy cell.

The electronics module 300 may further comprise a communicator (not shown) for communicating with an external device such as a mobile device. The communicator may be a mobile/cellular communicator operable to communicate the data wirelessly via one or more base stations. The communicator may provide wireless communication capabilities for the wearable article and enables the wearable article to communicate via one or more wireless communication protocols such as used for communication over: a wireless wide area network (WWAN), a wireless metroarea network (WMAN), a wireless local area network (WLAN), a wireless personal area network (WPAN), Bluetooth ® Low Energy, Bluetooth ® Mesh, Bluetooth ® 5, Thread, Zigbee, IEEE 802.15.4, Ant, a near field communication (NFC), a Global Navigation Satellite System (GNSS), a cellular communication network, or any other electromagnetic RF communication protocol.. The cellular communication network may be a fourth generation (4G) LTE, LTE Advanced (LTE-A), LTE Cat-M1 , LTE Cat-M2, NB-loT, fifth generation (5G), sixth generation (6G), and/or any other present or future developed cellular wireless network. A plurality of communicators may be provided for communicating over a combination of different communication protocols.

The electronics module 300 may comprise an input unit (not shown). The input unit enables the electronics module 300 to receive a user input for controlling the operation of the electronics module 300. The input unit may be any form of input unit capable of detecting an input event. The input event is typically an object being brought into proximity with the electronics module 300.

In some examples, the input unit comprises a user interface element such as a button. The button may be a mechanical push button.

In some examples, the input unit comprises an antenna. In these examples, the input event is detected by a current being induced in the first antenna. The mobile device is powered to induce a magnetic field in an antenna of the mobile device. When the mobile device is placed in the magnetic field of the antenna, the mobile device induces current in the antenna.

In some examples, the input unit comprises a sensor such as a proximity sensor or motion sensor. The sensor may be a motion sensor that is arranged to detect a displacement of the electronics module 300 caused by an object being brought into proximity with the electronics module 300. These displacements of the electronics module 300 may be caused by the object being tapped against the electronics module 300. Physical contact between the object and the electronics module 300 is not required as the electronics module 300 may be in a holder such as a pocket of the wearable article. This means that there may be a fabric (or other material) barrier between the electronics module 300 and the object. In any event, the object being brought into contact with the fabric of the pocket will cause an impulse to be applied to the electronics module 300 which will be sensed by the sensor.

It will be appreciated that a physical coupling between the electronics module 300 and the connection regions 111 is not required in all examples. The connection regions 111 may couple to a communication interface of the wearable article such as an inductive coil. The electronics module 300 may comprise a corresponding inductive coil to allow for inductive communication between the wearable article and the electronics module 300.

At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as ‘component’, ‘module’ or ‘unit’ used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term “comprising” or “comprises” means including the component(s) specified but not to the exclusion of the presence of others.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.