Conductive Thermal Transfer Adhesive for Washable Textile Connections

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Solution Overview

Problem

Existing methods for creating electrical connections on smart textiles are not suitable due to their complexity, lack of resistance to washing processes, and potential damage to the textile material, and conventional soldering or crimp connections are not optimal for this application.

Innovation Solution

The use of an electrically conductive thermal transfer adhesive is applied between conductive elements on a textile carrier material, melted under pressure to create a secure and permanent electrical connection, which also mechanically fixes the elements, allowing for easy and clean processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering or crimp connections are used for electrical connections on smart textiles, then electrical connectivity is achieved, but the textile material is damaged or visibly impaired

Engineering Contradiction:

Improveelectrical connectivityVSAvoidtextile material damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a textile-compatible adhesive as an intermediary substance between the electrical connection components and the textile material. This adhesive enables secure mechanical and electrical connection without directly damaging the textile fibers, unlike soldering or crimping methods that cause visible impairment and structural damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical connection methods (soldering, crimping) with an adhesive bonding system. This substitution eliminates the mechanical stress and heat application that damage textiles, while still achieving reliable electrical connectivity through the adhesive's conductive properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If conventional adhesives or silver-filled epoxy resin are used to fix conductors to textile, then mechanical fixation is achieved, but the manufacturing process becomes extremely complex

Engineering Contradiction:

Improvemechanical fixationVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single adhesive material: mechanical bonding, electrical conduction, and textile compatibility. This consolidation eliminates the need for separate adhesive application steps, conductor stripping procedures, and complex curing processes required by conventional methods, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The adhesive used in the patent serves multiple purposes simultaneously: it provides mechanical fixation of conductors to the textile, establishes electrical connectivity, and ensures washing resistance. This multi-functionality replaces the need for multiple specialized materials and processes, significantly reducing manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If thermal transfer adhesives are used for connecting fabrics, then mechanical connection is achieved, but electrical conductivity is not provided

Engineering Contradiction:

Improvemechanical connectionVSAvoidelectrical conductivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a composite adhesive material that combines the mechanical bonding properties of thermal transfer adhesives with electrically conductive fillers or components. This composite structure enables the adhesive to simultaneously provide strong mechanical connection and reliable electrical conductivity, overcoming the limitation of conventional thermal transfer adhesives.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the electrical conductivity parameter of the thermal transfer adhesive by incorporating conductive materials or adjusting its composition. This parameter change transforms the adhesive from a purely mechanical bonding agent into a dual-function material that provides both mechanical strength and electrical connectivity.

Inventive Principle:

Principle #35Parameter changes

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

This method enables a simple, reliable, and durable electrical connection on smart textiles that is resistant to washing and does not damage the material, while also providing mechanical fixation and easy production.

Implementation Method 1

the thermal transfer adhesive is melted under pressure, such that the liquid thermal transfer adhesive at least partially surrounds the first and second conductive element

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

after the thermal transfer adhesive has hardened

Methodology Applied

Scientific EffectPhase change (hardening): Phase Change

Data Source

PatentUS11764491B2Electrical connection on a textile carrier material

Publication Date: 2023.09.19 ADAPTIVE REGELSYST

AI summary

Various embodiments of the present disclosure are directed to electrically conductive connection between a first electrically conductive element and a second electrically conductive element on a textile carrier material. In one example embodiment, the electrically conductive connection includes an electrically conductive thermal transfer adhesive arranged on the carrier material and creates an electrically conductive connection between the first conductive element and the second conductive element. The electrically conductive connection is positioned in electrically conductive contact with the first conductive element and the second conductive element.