Chain-Stitched Conductive Wiring That Prevents Slack and Kinking
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Solution Overview
Problem
Conventional metal cables do not conform smoothly to fabrics, tend to slacken, kink, and are difficult to use due to structural issues such as tangling and separation of components.
Innovation Solution
A conductive cable integrating a coiled electric wire sewn under the loops of a chain-stitched yarn, with optional core yarn inside, using chain stitching to ensure smooth conformance to fabrics and prevent slackening and kinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive wire is wound around a core to reduce slack and improve handling, then the cable structure becomes more stable, but the core and spiral structure may move out of position due to abrasion or expansion/contraction, resulting in disconnection
Solution Approach 1:
The patent merges the conductive wire and chain-stitched yarn into a single integrated structure through chain stitching. The conductive wire is sewn under the loops of the chain-stitched yarn, creating a unified assembly where the wire and yarn move together as one unit, eliminating relative movement and position maintenance issues between separate components.
Solution Approach 2:
The conductive wire is nested within the loops of the chain-stitched yarn structure. The wire passes through and is secured by the continuous loops, creating a nested configuration where the inner element (wire) is held and protected by the outer structure (yarn loops), preventing displacement while maintaining flexibility.
2Reliability
If the outside of the spiral structure is covered with resin, tube, or braid to prevent internal structure exposure, then the structure is protected, but the outer diameter increases and the structure becomes stiffer, making the cable difficult to bend or twist
Solution Approach 1:
The chain-stitched yarn structure acts as a flexible protective shell around the conductive wire. Unlike rigid resin or tube coverings, the knitted yarn structure provides protection while maintaining flexibility, allowing the cable to bend and twist easily. The looped structure of the yarn naturally accommodates deformation without breaking or restricting movement.
3Reliability
If conventional metal cables are used for electrical connection, then conductivity is achieved, but the cables do not conform smoothly to fabrics and are difficult to use
Solution Approach 1:
The patent creates a composite structure combining a conductive wire (for electrical conductivity) with a chain-stitched yarn (for fabric conformance). The yarn component allows the cable to behave like a textile, conforming smoothly to fabrics, while the embedded conductive wire maintains electrical conductivity. This composite approach integrates the benefits of both materials without the drawbacks of using metal cable alone.
Data Source
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AI summary
A conductive cable includes a coiled electric wire 7 and a chain-stitched yarn 4, the chain-stitched yarn 4 being continuously chain-stitched, the coiled electric wire 7 being sewn under loops 3 of the chain-stitched yarn 4, and the coiled electric wire 7 and the chain-stitched yarn 4 being integrated. A method for producing the conductive cable includes performing chain stitching using a chain stitch sewing machine so that the loops 3 of the chain-stitched yarn 4 are continuously formed on one face of a sheet, and sewing the coiled electric wire 7 under the loops of the chain-stitched yarn when the chain stitching is performed. A core yarn may be further present inside the coil formed by the coiled electric wire 7. Thus, a conductive cable that conforms smoothly to fabrics, does not slacken unnecessarily, does not kink, and is easy to use is provided.