Composite Yarn Structure for Secure Component Support in Weaving
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Solution Overview
Problem
Existing composite yarns face challenges in efficiently supporting electronic components during weaving or knitting processes due to complex fixation methods, component movement within fabrics, and issues with antenna winding, leading to potential damage and production inefficiencies.
Innovation Solution
A composite yarn design featuring an electrically conductive yarn supporting an electronic component, protected by a protective insulating yarn, with a loop-like portion for secure adhesion and electromagnetic coupling, and connected by a connective insulating yarn, allowing for efficient manufacturing and high durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic components are fixed on yarn core by winding or arranging between core and covering fiber, then electronic components can be supported on composite yarn, but additional complex job steps are required and it is difficult to fix components without gap
Solution Approach 1:
The electronic component is nested within the tubular knitted fabric structure, which is formed by knitting the conductive yarn itself. The component is positioned in the cavity created by the knitted structure, eliminating the need for separate fixation steps while ensuring gap-free contact through the flexible knitted enclosure.
Solution Approach 2:
The conductive yarn serves dual purposes: it forms the structural basis of the composite yarn and simultaneously creates the tubular knitted fabric that houses and secures the electronic component. The knitting process itself provides the fixation mechanism, eliminating the need for additional fixation operations.
2Reliability
If electronic component is accommodated within tubular knitted fabric, then component is protected, but component moves and shifts within the fabric and is susceptible to damage
Solution Approach 1:
The tubular knitted fabric acts as a flexible shell that conforms to the electronic component's shape and size. The knitted structure's inherent flexibility allows it to adapt and紧紧包围 the component, preventing movement while accommodating thermal expansion and mechanical deformation without causing damage.
Solution Approach 2:
The knitted fabric structure dynamically adapts to the electronic component, providing tight enclosure when needed while maintaining flexibility for movement and deformation. The dynamic nature of the knitted structure allows it to respond to mechanical stresses by adjusting its configuration, thereby securing the component during both static and dynamic conditions.
3Reliability
If antenna line is wound around RFID module, then antenna can be connected to module, but it has problem for commercial production due to complexity
Solution Approach 1:
The antenna function and the structural yarn are merged into a single entity. The conductive yarn serves both as the mechanical structure of the composite yarn and as the antenna element, eliminating the need for separate antenna winding operations and integrating the antenna creation into the yarn manufacturing process itself.
Solution Approach 2:
The conductive yarn performs multiple functions simultaneously: it provides the structural framework of the composite yarn, acts as the antenna element for RFID communication, and forms the tubular knitted fabric that houses the electronic component. This multi-functionality eliminates several separate manufacturing steps and simplifies production.
4Ease of manufacture
If composite yarn is made with conventional materials, then yarn can be produced, but it lacks flexibility, bending durability, and stretch durability required for weaving and knitting
Solution Approach 1:
The invention uses composite materials comprising conductive fibers combined with flexible, durable textile materials in a knitted structure. This composite construction provides both the electrical conductivity needed for antenna function and the mechanical properties (flexibility, bend durability, stretch durability) required for weaving and knitting applications.
Data Source
Figure 1(a)~2(c)
Figure 3
AI summary
The composite yarn A according to the invention comprises: a yarn core B comprising plural electrically conductive yarns 11 that support electronic components 10 and have a pre-determined length, and plural connective insulating yarns 12 aligned in the lengthwise direction of the yarn core and connecting ends of the electrically conductive yarns; and a protective insulating yarn 13 wound on the yarn core B. The composite yarn has the electrically conductive yarns supporting the electronic components. The composite yarn has flexibility, durability to stretch, and bending durability and endures weaving, knitting, and use after weaving or knitting. The composite yarn can be manufactured efficiently.