Solar AI intelligent sportswear

Abstract

The invention belongs to the related technical field of intelligent sportswear, and particularly relates to a solar AI intelligent sportswear, which comprises an outdoor jacket main body, at least three flexible amorphous silicon film power generation modules, an energy management module, an energy storage unit, an electricity load and a flexible conductive circuit for interconnecting the flexible amorphous silicon film power generation modules, the energy management module, the energy storage unit and the electricity load. The flexible amorphous silicon film power generation modules are optimally arranged in high-sunlight areas such as the rear of the brim and the shoulders and are combined with the garment through the hot-pressing composite technology, sewing needle holes are avoided, the original elasticity, soft touch feeling and appearance smoothness of the garment are kept, and the service life of the garment is prolonged. The non-sensibility of the power generation function and the non-destructive effect of the clothes movement function are realized; according to the power generation module, ETFE / PI'sandwich 'packaging and ultrasonic welding edge sealing are adopted, and a waterproof moisture-permeable hot melt adhesive composite technology is matched, so that multi-layer protection is jointly formed.

Description

Technical Field

[0001] This invention belongs to the technical field of smart sportswear, specifically relating to solar-powered AI smart sportswear. Background Technology

[0002] With the increasing popularity of outdoor sports and the miniaturization of electronic devices, outdoor wearers have a growing demand for intelligent clothing, such as built-in heating, GPS tracking, vital sign monitoring, and emergency lighting. However, the power supply for these functions has traditionally relied on bulky portable power banks, becoming a bottleneck for user experience. Flexible solar cells, especially amorphous silicon thin films, are considered an ideal wearable energy solution due to their light weight, thinness, flexibility, and good performance in low light conditions.

[0003] Problems with existing technology: Existing products are mostly simple stitching or external attachments, which compromises the waterproofness, breathability, and overall aesthetics of the jacket. Furthermore, the power generation module itself is not resistant to repeated bending, friction, and washing. Summary of the Invention

[0004] The purpose of this invention is to provide solar-powered AI smart sportswear, which can solve the problems of existing products that are mostly simply sewn or attached, which compromise the waterproofness, breathability and overall aesthetics of the jacket, and the fact that the power generation module itself is not resistant to repeated bending, friction and washing.

[0005] The specific technical solution adopted by this invention is as follows: The solar-powered AI smart sportswear includes a main body of a windbreaker, a flexible amorphous silicon thin-film power generation module, an energy management module, an energy storage unit, an electrical load, and flexible conductive lines interconnecting them. The flexible amorphous silicon thin-film power generation module is provided in at least three parts.

[0006] The three flexible amorphous silicon thin-film power generation modules are respectively installed behind the brim of the hood of the jacket and on the shoulder of the jacket. The flexible amorphous silicon thin-film power generation module adopts a "sandwich" packaging structure: from top to bottom, it consists of an ETFE protective layer, an amorphous silicon thin-film power generation layer, and a PI substrate. Its edges are sealed by ultrasonic welding and connected to flexible conductive lines through waterproof electrical connectors.

[0007] The flexible amorphous silicon thin-film power generation module is combined with the main body of the jacket by means of a layer of waterproof and breathable hot melt adhesive film with microporous structure (such as TPU hot melt adhesive), which is hot-pressed with the outer fabric of the garment under specific temperature and pressure to form a strong and soft bonding interface.

[0008] The energy management module is a miniaturized energy management circuit board, and the energy storage unit is a flat lithium polymer battery. The energy management circuit board and the lithium polymer battery are encapsulated together inside an energy management compartment, which is located in the lining area on the lower left side of the main body of the jacket.

[0009] The energy management compartment is enclosed in a removable, independent waterproof compartment, which is sewn or hung on the inner lining of the main body of the jacket.

[0010] The electrical load includes a heating element module, a GPS sensor module, a shoulder lighting LED module, a heart rate detection module, a body temperature monitoring module, and a mobile device charging module. The heating element module is located at the cuffs, front chest, and back of the main body of the jacket. The GPS sensor module is located on the upper back of the main body of the jacket. The body temperature monitoring module is located on the upper front chest and back of the main body of the jacket. The mobile device charging module is located in the left chest pocket area of ​​the main body of the jacket.

[0011] A method for preparing solar-powered AI smart sportswear, characterized by the following steps: Step 1: Design and fabrication of power generation modules 1. Based on the garment pattern, design three irregularly shaped flexible amorphous silicon thin-film power generation modules: one flexible amorphous silicon thin-film power generation module for the back of the trapezoidal brim of the main body of the jacket, and two long strip-shaped flexible amorphous silicon thin-film power generation modules for the shoulders of the main body of the jacket.

[0012] 2. Purchase flexible amorphous silicon thin film sheets (PI substrate, rated voltage 5V, power approximately 1.5W per sheet).

[0013] 3. Use an ultrasonic cutting machine to cut the material according to the design shape.

[0014] 4. Encapsulation: Place the cut battery cells between the ETFE film and the PI film, seal along the edges with an ultrasonic welding machine, and lead out the positive and negative electrode wires. Then, heat-press a 0.1mm thick perforated TPU film onto the back of the PI film.

[0015] Step 2: Fabric Pretreatment 1. At the predetermined integration location of the Gore-Tex fabric on the outer layer of the jacket body, a breathable mesh area slightly smaller than that of the flexible amorphous silicon thin-film power generation module is laser-cut (for the wires to pass through the inner layer).

[0016] 2. Temporarily affix a high-temperature resistant protective film to the back of this area.

[0017] Step 3: Hot-pressing lamination of the module and garment 1. Place the flexible amorphous silicon thin-film power generation module (TPU film side down) precisely at the preset position on the fabric.

[0018] 2. Use a flatbed hot press to hot press for 25 seconds at 125℃ and 0.3MPa pressure.

[0019] 3. After cooling, the flexible amorphous silicon thin-film power generation module is firmly bonded to the main fabric of the jacket, and the interface is soft and flexible.

[0020] Step 4: Internal System Integration 1. Insert the wire through the breathable mesh into the inner lining of the jacket and lay it along the lining channel to the energy management compartment on the lower left side.

[0021] 2. Connect the wires to the input terminals of the management circuit board inside the energy management compartment.

[0022] 3. Place the energy management compartment into the specially designed waterproof compartment and sew the waterproof compartment bag onto the inner lining of the main body of the jacket, leaving only the USB port exposed.

[0023] 4. Lead wires from the output end of the energy management compartment to the electrical loads distributed throughout the garment.

[0024] Step 5: Testing and Verification 1. Power generation test: Under standard lighting conditions, the system can stably output ≥4W of power, which is sufficient to continuously power the heating element module and GPS sensor module, and slowly charge the built-in battery.

[0025] 2. Environmental testing: The system functions perfectly and there is no water leakage at the interfaces after passing simulated rainfall (IPX4), low temperature bending (-20℃, 1000 times) and limited machine washing (5 gentle cycles).

[0026] 3. User Testing: In a real-world hiking environment, users can operate without an external power source, using the clothing's self-heating function for over 8 hours, and can also recharge their mobile phones at any time.

[0027] The technical effects achieved by this invention are as follows: This invention optimizes the arrangement of multiple flexible amorphous silicon thin-film power generation modules in high-sunlight areas such as the back of the hat brim and the shoulders, and combines them with clothing through hot-pressing composite technology. This avoids sewing needle holes, maintains the original elasticity, soft touch, and smooth appearance of the clothing, and achieves seamless power generation and non-destructive movement of the clothing. By using ETFE / PI "sandwich" encapsulation and ultrasonic welding edge sealing for the power generation modules, combined with a waterproof and breathable hot melt adhesive composite process, multiple layers of protection are formed. This effectively ensures the waterproofness, scratch resistance, and operational reliability of the power generation unit under outdoor rain, snow, friction, and limited washing conditions, thereby extending the service life of the entire smart clothing system. By integrating core electronic components such as the energy management module and energy storage unit into a separate, detachable, waterproof compartment and using connectors, users can maintain, replace batteries, or upgrade components without the need for professional tools. Furthermore, the main body of the jacket is machine washable without obstruction, greatly improving user experience and product maintainability. The plug-and-play design of the energy management system and the ultrasonic welding and hot-pressing composite processes used in the power generation module ensure high compatibility with existing mature garment processing equipment and processes, which helps reduce production costs, ensure quality, and achieve large-scale production. Simultaneously, the system integrates multiple optional electrical loads, providing users with a customizable, multi-functional integrated smart outdoor wearable solution. Detailed Implementation

[0028] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0029] The solar-powered AI smart sportswear includes a main body of a windbreaker, a flexible amorphous silicon thin-film power generation module, an energy management module, an energy storage unit, an electrical load, and flexible conductive lines interconnecting them. There are at least three flexible amorphous silicon thin-film power generation modules.

[0030] Furthermore, three flexible amorphous silicon thin-film power generation modules are respectively installed behind the hood of the jacket and on the shoulders of the jacket. The flexible amorphous silicon thin-film power generation modules adopt a "sandwich" encapsulation structure: from top to bottom, there is an ETFE protective layer, an amorphous silicon thin-film power generation layer, and a PI substrate. The edges are sealed by ultrasonic welding and connected to flexible conductive lines through waterproof electrical connectors. By using a high light transmittance and scratch-resistant ETFE film as the upper protective layer and PI as the lower substrate, and sealing the edges with ultrasonic welding, the basic waterproof function of the garment is ensured.

[0031] Furthermore, the flexible amorphous silicon thin-film power generation module is combined with the main body of the jacket by means of a layer of waterproof and breathable hot melt adhesive film with microporous structure (such as TPU hot melt adhesive), which is hot-pressed with the outer fabric of the garment under specific temperature and pressure to form a strong and soft bonding interface. This method can form a strong, waterproof and breathable connection between the fabric and the module, avoiding water leakage caused by sewing needle holes, and maintaining the original elasticity and soft touch of the garment fabric. The energy management module is a miniaturized energy management circuit board, and the energy storage unit is a flat lithium polymer battery. The energy management circuit board and the lithium polymer battery are encapsulated together inside an energy management compartment, which is located in the inner lining area on the lower left side of the main body of the jacket. The energy management compartment is enclosed in a removable, independent waterproof compartment, which is sewn or hung on the inner lining of the jacket body, making it easy to remove the energy management compartment and thus facilitating unimpeded machine washing of the jacket body. The electrical load includes a heating element module, a GPS sensor module, a shoulder LED lighting module, a heart rate detection module, a body temperature monitoring module, and a mobile device charging module. The heating element module is located at the cuffs, front chest, and back of the main body of the jacket. The GPS sensor module is located on the upper back of the main body of the jacket. The body temperature monitoring module is located on the front chest and upper back of the main body of the jacket. The mobile device charging module is located in the left chest pocket area of ​​the main body of the jacket.

[0032] The method for preparing solar-powered AI smart sportswear is as follows: Step 1: Design and fabrication of power generation modules 1. Based on the garment pattern, design three irregularly shaped flexible amorphous silicon thin-film power generation modules: one flexible amorphous silicon thin-film power generation module for the back of the trapezoidal brim of the main body of the jacket, and two long strip-shaped flexible amorphous silicon thin-film power generation modules for the shoulders of the main body of the jacket.

[0033] 2. Purchase flexible amorphous silicon thin film sheets (PI substrate, rated voltage 5V, power approximately 1.5W per sheet).

[0034] 3. Use an ultrasonic cutting machine to cut the material according to the design shape.

[0035] 4. Encapsulation: Place the cut battery cells between the ETFE film and the PI film, seal along the edges with an ultrasonic welding machine, and lead out the positive and negative electrode wires. Then, heat-press a 0.1mm thick perforated TPU film onto the back of the PI film.

[0036] Step 2: Fabric Pretreatment 1. At the predetermined integration location of the Gore-Tex fabric on the outer layer of the jacket body, a breathable mesh area slightly smaller than that of the flexible amorphous silicon thin-film power generation module is laser-cut (for the wires to pass through the inner layer).

[0037] 2. Temporarily affix a high-temperature resistant protective film to the back of this area.

[0038] Step 3: Hot-pressing lamination of the module and garment 1. Place the flexible amorphous silicon thin-film power generation module (TPU film side down) precisely at the preset position on the fabric.

[0039] 2. Use a flatbed hot press to hot press for 25 seconds at 125℃ and 0.3MPa pressure.

[0040] 3. After cooling, the flexible amorphous silicon thin-film power generation module is firmly bonded to the main fabric of the jacket, and the interface is soft and flexible.

[0041] Step 4: Internal System Integration 1. Insert the wire through the breathable mesh into the inner lining of the jacket and lay it along the lining channel to the energy management compartment on the lower left side.

[0042] 2. Connect the wires to the input terminals of the management circuit board inside the energy management compartment.

[0043] 3. Place the energy management compartment into the specially designed waterproof compartment and sew the waterproof compartment bag onto the inner lining of the main body of the jacket, leaving only the USB port exposed.

[0044] 4. Lead wires from the output end of the energy management compartment to the electrical loads distributed throughout the garment.

[0045] Step 5: Testing and Verification 1. Power generation test: Under standard lighting conditions, the system can stably output ≥4W of power, which is sufficient to continuously power the heating element module and GPS sensor module, and slowly charge the built-in battery.

[0046] 2. Environmental testing: The system functions perfectly and there is no water leakage at the interfaces after passing simulated rainfall (IPX4), low temperature bending (-20℃, 1000 times) and limited machine washing (5 gentle cycles).

[0047] 3. User Testing: In a real-world hiking environment, users can operate without an external power source, using the clothing's self-heating function for over 8 hours, and can also recharge their mobile phones at any time.

[0048] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described or explained in this invention are implemented according to conventional methods in the art unless otherwise specified or limited.

Claims

1. Solar-powered AI smart sportswear, characterized by: It includes the main body of the jacket, a flexible amorphous silicon thin-film power generation module, an energy management module, an energy storage unit, an electrical load, and flexible conductive lines interconnecting them, wherein at least three flexible amorphous silicon thin-film power generation modules are provided.

2. The solar-powered AI smart sportswear according to claim 1, characterized in that: The three flexible amorphous silicon thin-film power generation modules are respectively installed behind the hood of the jacket and on the shoulder of the jacket. The flexible amorphous silicon thin-film power generation module adopts a "sandwich" packaging structure: from top to bottom, it consists of an ETFE protective layer, an amorphous silicon thin-film power generation layer, and a PI substrate. Its edges are sealed by ultrasonic welding and connected to flexible conductive lines through waterproof electrical connectors.

3. The solar-powered AI smart sportswear according to claim 1, characterized in that: The flexible amorphous silicon thin-film power generation module is combined with the main body of the jacket by means of a layer of waterproof and breathable hot melt adhesive film with microporous structure, which is hot-pressed with the outer fabric of the garment under specific temperature and pressure to form a strong and soft bonding interface.

4. The solar-powered AI smart sportswear according to claim 1, characterized in that: The energy management module is a miniaturized energy management circuit board, and the energy storage unit is a flat lithium polymer battery. The energy management circuit board and the lithium polymer battery are encapsulated together inside an energy management compartment, which is located in the lining area on the lower left side of the main body of the jacket.

5. The solar-powered AI smart sportswear according to claim 4, characterized in that: The energy management compartment is enclosed in a removable, independent waterproof compartment, which is sewn or hung on the inner lining of the main body of the jacket.

6. The solar-powered AI smart sportswear according to claim 1, characterized in that: The electrical load includes a heating element module, a GPS sensor module, a shoulder lighting LED module, a heart rate detection module, a body temperature monitoring module, and a mobile device charging module. The heating element module is located at the cuffs, front chest, and back of the main body of the jacket. The GPS sensor module is located on the upper back of the main body of the jacket. The body temperature monitoring module is located on the upper front chest and back of the main body of the jacket. The mobile device charging module is located in the left chest pocket area of ​​the main body of the jacket.

7. The method for preparing solar-powered AI smart sportswear according to claim 1, characterized in that: Includes the following steps: Step 1: Design and fabrication of power generation modules (1). Based on the garment pattern, design three irregularly shaped flexible amorphous silicon thin film power generation modules: one flexible amorphous silicon thin film power generation module for the back of the trapezoidal brim of the main body of the jacket and two long strip flexible amorphous silicon thin film power generation modules for the shoulders of the main body of the jacket. (2) Purchase flexible amorphous silicon thin film sheets (PI substrate, rated voltage 5V, power approximately 1.5W per sheet); (3) Cut the material to the designed shape using an ultrasonic cutting machine; (4). Encapsulation: Place the cut battery cells between the ETFE film and the PI film, seal along the edge with an ultrasonic welding machine, and lead out the positive and negative electrode wires. Heat press a 0.1mm thick perforated TPU film onto the back of the PI film. Step 2: Fabric Pretreatment (1). At the predetermined integration position of the Gore-Tex fabric on the outer layer of the main body of the jacket, a breathable mesh area slightly smaller than that of the flexible amorphous silicon thin film power generation module is cut out by laser. (2) Temporarily attach a high-temperature resistant protective film to the back of this area; Step 3: Hot-pressing lamination of the module and garment (1) Place the flexible amorphous silicon thin-film power generation module (TPU film side down) precisely at the preset position on the fabric; (2). Use a flatbed hot press to hot press for 25 seconds at 125℃ and 0.3MPa pressure; (3) After cooling, the flexible amorphous silicon thin film power generation module is firmly bonded to the main fabric of the jacket, and the interface is soft and flexible; Step 4: Internal System Integration (1). The wire is introduced into the inner lining of the jacket through the breathable mesh and laid along the inner lining channel to the energy management compartment on the lower left side of the rib. (2) Connect the wires to the input terminal of the management circuit board inside the energy management compartment; (3) Place the energy management compartment into the specially made waterproof compartment and sew the waterproof compartment bag onto the inner lining of the main body of the jacket, leaving only the USB interface exposed; (4) Lead wires from the output end of the energy management compartment to the electrical loads distributed throughout the garment; Step 5: Testing and Verification (1). Power generation test: Under standard illumination, the system can stably output ≥4W of power, which is sufficient to continuously power the heating element module and the GPS sensor module, and slowly charge the built-in battery; (2). Environmental test: The system functions well and there is no water leakage at the interface after passing the simulated rainfall (IPX4), low temperature bending (-20℃, 1000 times) and limited machine washing (5 gentle modes). (3). User test: In a real hiking environment, users can disconnect from the external power source and use the clothing's self-heating function for more than 8 hours, and replenish the power of their mobile phones at any time.