How to sew a patch onto a conductive jacket
Antoine Gouin
This article details the repair of conductive jackets and conductive fabrics. Imex Sport strongly advises against the application of patches on protective clothing (jacket, pants, glove, etc.), since there is no way to guarantee that such a repair will offer the same level of safety as the original fabric of the clothing.
There are a number of temporary repairs that can extend the life of a conductive jacket, especially when you get caught short during a tournament. See the article Emergency Repair of conductive fabrics for some examples. On the other hand, once you get home, we recommend that you take the time to make a more lasting repair.
Why use a patch?
A patch is a "permanent" repair of the conductive jacket (or bib) in two situations:
- When there is a small hole or tear in the material and its edges are frayed
- When the jacket or bib has a spot that is too degraded and which no longer meets the conductivity standards (5 Ohms)
Since the patch is made of the same material as the jacket or bib, and because it is sewn in place, the result is a very durable repair. However, a patch is not always necessary. If your jacket has a small hole or tear with clean edges, it is better to mend it instead of resorting to a patch.
What are the limits of patches?
If the hole, tear or degraded area is too large or the are too many of them, the jacket may be refused for the tournament even if patches are properly sewn. Consider the following regulation, taken from the FEQ rulebook and which only applies for tournaments in Quebec (translated from French):
7) Clothing and equipment: [...] Electric jackets: the tolerance is set at 10 ohms (instead of 15), with two small "patches" (repairs by fitting a piece of fabric) at most for electric jackets. [...]
In the case of national and international tournaments, the regulations do not specify any limit on the number of patches, nor anything regarding their size or location. As long as the patches share all of the properties of the conductive jacket itself, and are properly sewn to prevent a blade from getting caught, there is normally no problem with the jacket being approved.
Where do I find a patch?
The fabric used for conductive jackets is not readily available in stores. You can get the necessary fabric in three different ways:
- When you buy your jacket
- Some manufacturers like Allstar include in their packaging a piece of conductive fabric alongside their conductive jackets for just this situation. Keep it, you don't know when it will be of use to you.
- By reusing an old jacket
- If you have an old conductive jacket that is no longer tournament-approved, you can cut out the parts that still meet the standards and use those parts as patches.
- By purchasing a patch kit
- Imex Sport offers a patch kit, available in the Tools & Testers section, which includes a piece of conductive fabric, a needle and thread.
How do I know where to place my patch?
In the event that you need to repair a hole or tear, it is quite easy to find where to put the patch. However, when it comes to repairing a dead spot, it is more difficult to find it with the naked eye.
Have an armorer (in tournament) or a qualified person (at your club) thoroughly test your jacket to accurately identify any dead zones. Using a permanent marker, trace the exact outline of the dead spots.
After this, you have to cut the patch material. Your patch should completely cover the dead zone and overlap the "good" zone by about 1 cm. You will need one patch for each dead spot.
How to sew a patch
The patch can be sewn by hand or with a sewing machine. It is possible to use a standard sewing thread, but the sewing must meet a few criteria. The seam should be:
- Tight enough to prevent a blade from getting caught under the patch from any angle.
- Tight enough to ensure strong and permanent electrical contact between the patch and the conductive jacket.
- Sufficiently spaced so as not to interfere with the electrical contact between a blade and the patch, when such contact is made on the seam. In the end, the conductive jacket and the patch will have to conduct electricity over their entire surface.
- Strong enough to stand the test of time.
Metallic threads are present on both sides of the patch. Therefore it is not necessary to fold over the edges of the patch before sewing it on. However, be sure to cut the patch so that you have the cleanest possible edges to prevent them from fraying.
Conclusion
A well-sewn patch can greatly extend the life of your conductive jacket. To pass the test, it must be properly sewn, but without using too much thread. For smaller repairs, it may be sufficient to mend the jacket. The more subtle and the higher quality the result is, the better.
Don't wait to get caught off guard. Get your patch kit now in our Tools & Testers section.
