Conductive Core Fabric Stitched Yarn Durability
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Solution Overview
Problem
Conductive fabrics produced using conductive yarns are limited in the types of yarns and constructions possible, which restricts the integration of various electronics and may not be durable enough for repeated use.
Innovation Solution
The use of a conductive core within the fabric, where a yarn is stitched through the core, allowing for the integration of electronic components and improved durability by eliminating the need for conductive yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conductive yarns are used to produce conductive fabrics, then the fabric can conduct electricity, but the types of yarns and constructions possible are limited
Solution Approach 1:
The fabric structure is segmented into distinct functional layers: a non-conductive base fabric and a separate conductive core. This segmentation allows independent optimization of each layer's properties, enabling versatile fabric constructions while maintaining reliable electrical conductivity through the dedicated conductive core.
Solution Approach 2:
A non-conductive barrier layer is introduced as an intermediary between the conductive core and the external environment. This intermediary layer protects the conductive core while allowing the fabric to achieve versatile constructions and patterns without compromising the electrical conductivity of the core.
2Reliability
If conductive yarns are used in fabrics, then electrical conductivity is achieved, but durability against repeated wash cycles and surface abrasion is insufficient
Solution Approach 1:
The conductive function is extracted from the yarn structure and concentrated into a separate conductive core. This extraction allows the yarn to focus on mechanical durability and fabric construction flexibility, while the dedicated conductive core handles electrical conductivity and withstands repeated wash cycles and surface abrasion.
Solution Approach 2:
The fabric employs a composite structure combining non-conductive base fabric material with a conductive core material. This composite approach enables the fabric to simultaneously achieve high durability through the robust base fabric and reliable electrical conductivity through the specialized conductive core.
3Adaptability or versatility
If conductive yarns are used, then the fabric can support electronic components, but the integration of various electronics is restricted
Solution Approach 1:
The conductive core serves multiple functions: providing electrical conductivity, supporting electronic components, and enabling various electronic functionalities such as sensors, lights, and communication circuits. This multi-functionality simplifies the overall device complexity while enhancing electronic integration capability.
Solution Approach 2:
The conductive core extends through the fabric in a third dimension, creating a continuous conductive pathway that enables electronic integration without complicating the two-dimensional yarn and construction structure. This dimensional approach allows versatile electronic functionality while maintaining simple fabric construction.
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 approach enables the creation of fabrics that can conduct electricity, support electronic components, and withstand repeated wash cycles and surface abrasion, while allowing for various electronic functionalities such as sensors, lights, and communication circuits.
Implementation Method 1
a conductive core (102) and a yarn (104). In some embodiments, the conductive core (102) is an electrically conductive film
Data Source
AI summary
A stitched fabric including a conductive core and a yarn stitched through and forming stitch holes in the conductive core, where the yarn extends over at least a majority of a width and a length of the fabric. The yarn and the conductive core may be free from contact by another layer on either side of the conductive core. In some circumstances, a barrier layer is disposed over at least one side of the conductive core and a melted portion of the barrier layer fills a portion of the stitch holes.