Conductive Fabric Assembly for Embedded Electrical Components
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Solution Overview
Problem
Incorporating electrical components into fabric items is challenging due to the flexibility of fabric, which can damage signal paths or dislodge components when bent or stretched, making it difficult to mount structures securely.
Innovation Solution
Interlacing equipment with individually adjustable components allows for the insertion and embedding of electrical components during fabric creation, using tools like warp and weft strand positioning equipment, insulation removal tools, and heating tools to securely attach components to conductive strands within the fabric without disrupting the interlacing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are mounted on fabric, then enhanced functionality is provided, but the components may become dislodged or signal paths damaged when fabric is bent and stretched
Solution Approach 1:
The fabric is segmented into interlaced strands (warp and weft) that can move independently, allowing the fabric to flex and stretch without transmitting stress to the electrical components. The components are mounted in the spaces between strands rather than directly on the fabric surface, isolating them from mechanical deformation.
Solution Approach 2:
Electrical components are nested within the fabric structure by positioning them in gaps between interlaced strands. The fabric strands are arranged to surround and protect the components, effectively nesting the components within the fabric's three-dimensional structure rather than mounting them on the surface.
2Ease of operation
If fabric is made flexible for comfort and wearability, then ease of operation is improved, but mounting structures securely becomes difficult
Solution Approach 1:
The fabric structure is designed to be dynamic, with strands that can move and adjust independently during interlacing. This allows the fabric to maintain flexibility for comfort while providing stable positions for component mounting. The interlacing pattern creates a dynamic structure that adapts to both flexibility requirements and mounting requirements.
Solution Approach 2:
The interlacing strands act as intermediaries between the fabric's flexible nature and the need for stable component mounting. The strands create a stable framework through their interlaced pattern, mediating between the flexible fabric base and the rigid electrical components, allowing both flexibility and secure mounting to coexist.
3Stability of the object's composition
If electrical components are inserted during fabric creation, then integration is improved, but interlacing operations may be disrupted
Solution Approach 1:
Gaps or spaces are preliminarily created in the fabric structure during the interlacing process at predetermined locations where electrical components will be inserted. These gaps are prepared in advance by adjusting the interlacing pattern or leaving intentional spaces, so that component insertion does not require disrupting the interlacing operations later.
Solution Approach 2:
The interlacing operations continue continuously while electrical components are inserted into pre-prepared gaps. The insertion process does not interrupt the overall interlacing flow, as components are placed into spaces that were already created as part of the normal interlacing pattern, maintaining continuity of the manufacturing process.
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
Enables the secure integration of electrical components into fabric items, ensuring they remain attached and functional even when the fabric is bent or stretched, while maintaining the fabric's integrity and functionality.
Implementation Method 1
The insulation removal tool may include a laser that ablates an outer insulating coating to expose a conductive core on each conductive strand.
Implementation Method 2
a heating tool such as an inductive heating tool, hot air, or laser may be used to reflow solder between the electrical component and the conductive strands
Implementation Method 3
a heating tool such as an inductive heating tool, hot air, or laser may be used to reflow solder
Implementation Method 4
heat may also be applied to melt an encapsulant material such as thermoplastic. The encapsulant material may cover the conductive strands and fill in the grooves
Data Source
AI summary
Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.