Conductive Composite Yarn for Smart Garments
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Solution Overview
Problem
Conductive sewing threads face challenges in withstanding repeated bends and stresses during sewing operations without breaking, and in preventing electrical short circuits when sewn across themselves, while maintaining high conductivity.
Innovation Solution
A conductive composite yarn/sewing thread is developed with a core of high-gauge conductive metal strands, wrapped by inner and outer synthetic or natural fiber covers, and treated with a bonding agent and optionally a lubricant, allowing for flexible and durable conductive patterns in fabrics and garments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic strand is used to provide conductivity in the sewing thread, then the conductive capability is improved, but the thread becomes prone to breaking under repeated bends and stresses during sewing operations
Solution Approach 1:
The patent applies composite materials by combining a metallic core (providing conductivity) with synthetic or natural fiber covers (providing strength and flexibility). This composite structure allows the thread to maintain both conductive capability and resistance to breaking during sewing operations. The metallic core is protected by the outer fiber layers, preventing direct exposure to mechanical stresses while maintaining electrical conductivity.
Solution Approach 2:
The patent uses flexible fiber covers (synthetic or natural) as protective shells around the metallic core. These flexible covers allow the thread to bend and flex during sewing operations without breaking the rigid metallic core, thereby maintaining both conductivity and mechanical strength. The flexible shell structure accommodates the mechanical deformations while protecting the conductive element.
2Ease of manufacture
If the conductive thread is sewn across itself to create patterns, then the conductive patterns are formed, but electrical short circuits occur between the thread segments
Solution Approach 1:
The patent uses the fiber covers (synthetic or natural) as intermediary insulating layers between the metallic core and any contacting surfaces. When the thread is sewn across itself, the fiber covers prevent direct contact between metallic segments, thereby avoiding electrical short circuits while allowing the conductive pattern to be formed. The intermediary fiber layer acts as an electrical insulator while permitting mechanical interweaving.
Solution Approach 2:
The fiber covers serve as flexible insulating shells that wrap around the metallic core. These shells prevent electrical contact between adjacent or crossed thread segments while allowing the thread to be manipulated into various patterns. The flexible shell structure enables the thread to cross itself mechanically while maintaining electrical isolation between segments.
3Stability of the object's composition
If the metallic core is made thinner to increase flexibility, then the thread becomes more flexible for sewing, but the conductivity decreases
Solution Approach 1:
The patent uses composite materials where the metallic core provides conductivity and the fiber covers provide flexibility. This allows the overall thread structure to be flexible for sewing applications while the metallic core maintains sufficient thickness to ensure adequate conductivity. The composite structure decouples the flexibility requirement from the core dimensions.
Solution Approach 2:
The patent optimizes the parameters of the metallic core (such as gauge, material composition, and cross-sectional area) to achieve a balance between flexibility and conductivity. By carefully selecting the core parameters and combining them with appropriate fiber covers, the thread achieves both the flexibility needed for sewing and the conductivity required for electrical applications.
Data Source
AI summary
A conductive composite yarn having:a) a core formed of at least one metallic strand of 40 or higher gauge which is electrically conductive;b) at least one inner cover wrapped around the core in a first direction at a rate sufficient to provide substantially complete coverage of the core by the inner cover, wherein the inner cover is a natural or synthetic yarn;c) at least one outer cover wrapped around the at least one inner cover, wherein the outer cover is wrapped in a second direction opposite to a direction of a cover layer on which the outer cover is directly wrapped, at a rate sufficient to provide substantially complete cover of the cover layer on which the outer cover is directly wrapped;d) at least one bonding agent applied onto the at least one outer cover; ande) optionally, a lubricant.a conductive composite sewing thread therefrom, and use of the yarn/sewing thread in production of smart fabrics or smart garments having electrical segments, patterns, or grids therein.