Abstract: Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.

Abstract: Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.

Abstract: Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.

Abstract: Loom configurations and methods for efficiently manufacturing unique spiral-shaped fabrics. The loom introducing two weft yarn segments in the form of a continuous loop in each shed may be configured with one or two weft needles and is equipped with a knitting system to form a knitted selvedge along the outside circumference of the fabric. The knitted edge is used as reference to form weft yarn loops of different lengths. The opposite weft yarn loops are permanently secured around selected warp yarns. Alternatively intermediate length weft yarn loops may be created where the extremity of the loop is not bound to any warp yarn. Fiber architectures may be designed and woven which exhibit uniform fiber volume across the width of the fabric. Fiber architectures with greater fiber volume along the outside circumference of the fabric may also be prepared.

Abstract: Loom configurations and methods for efficiently manufacturing unique spiral-shaped fabrics. The loom introducing two weft yarn segments in the form of a continuous loop in each shed may be configured with one or two weft needles and is equipped with a knitting system to form a knitted selvedge along the outside circumference of the fabric. The knitted edge is used as reference to form weft yarn loops of different lengths. The opposite weft yarn loops are permanently secured around selected warp yarns. Alternatively intermediate length weft yarn loops may be created where the extremity of the loop is not bound to any warp yarn. Fiber architectures may be designed and woven which exhibit uniform fiber volume across the width of the fabric. Fiber architectures with greater fiber volume along the outside circumference of the fabric may also be prepared.