Braided Flat Conductive Tape for Flexible Curved Paths
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Solution Overview
Problem
Conductive tapes are inflexible when bent in the direction of their width, making it impractical to create curved conductors, and lack tension relief, which can lead to malfunction under stress from temperature variations and surface forces.
Innovation Solution
A method of braiding multiple strands of flat conductive tape together, allowing for flexibility and expansion, and applying adhesive in segments to secure the braided tape to a substrate while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flat conductive tape is used to create curved conductors, then the conductor can follow curved paths, but the tape is inflexible when bent in the direction of its width making curved conductors impractical
Solution Approach 1:
The flat conductive tape is divided into multiple strands that are braided together. Each strand remains relatively flat and conductive, while the braided structure as a whole gains flexibility in the width direction, enabling curved conductor paths.
Solution Approach 2:
Multiple flat conductive tape strands are combined into a braided composite structure. This composite maintains the electrical conductivity of individual flat tapes while achieving macroscopic flexibility through the braided configuration.
2Reliability
If tension relief is not included in the design, then the conductor structure remains simple, but the flat conductor may not operate as desired under stress from temperature variation and forces
Solution Approach 1:
The braided structure introduces dynamic flexibility to the conductor, allowing it to expand and contract in response to temperature variations and applied forces. The braided configuration acts as an inherent tension relief mechanism that maintains electrical connectivity while accommodating dimensional changes.
3Adaptability or versatility
If multiple flat conductors are integrated into a braided structure, then flexibility and expansion capability improve, but the structure becomes more complex
Solution Approach 1:
Multiple flat conductive tape strands are merged into a single braided conductor assembly. This combining approach achieves enhanced flexibility and expansion capability while maintaining a unified conductor structure that can be installed as a single component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of low-profile, flexible flat conductors that can follow curved paths and withstand temperature variations and forces, while securely adhering to a substrate without hindering flexibility.
Implementation Method 1
applying adhesive in segments, with each of the segment of the adhesive applied to only one of the strands of the braided flat conductive tape
Data Source
AI summary
A method of forming a flat conductor that includes aligning multiple strands of flat conductive tape adjacent to each other, and braiding the strands of flat conductive tape to each other by sequentially bending one of the strands of flat conductive tape over the other strands of flat conductive tape to create a braided flat conductive tape. Each end of the braided flat conductive tape is connected to an electrical assembly for carrying electrical current therethrough.