Conductive Fabric Protrusion Wire Connection Method
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Solution Overview
Problem
Existing methods for connecting conductive fabric to wires, such as crimping, are ineffective for non-malleable materials like conductive fabric, leading to mechanical and electrical connection failures under external strain.
Innovation Solution
A method involving a conductive fabric with a protrusion that is folded over a wire and secured with a device, such as a tie or heat shrink material, to create a stable mechanical and electrical connection without damaging the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping method is used to connect wire to conductive fabric, then secure mechanical connection is achieved, but conductive fabric is damaged (torn or ripped)
Solution Approach 1:
The patent introduces a connector as an intermediary component between the wire and conductive fabric. The connector has a crimpable body that mechanically engages with the conductive fabric through teeth or gripping surfaces, while a separate terminal receives the wire. This mediator allows the crimping force to be applied to the connector rather than directly to the conductive fabric, preventing damage while maintaining secure mechanical connection.
Solution Approach 2:
The connection system is divided into separate functional components: the connector body that interfaces with conductive fabric, the terminal that receives the wire, and the conductive fabric itself. This segmentation allows each component to be optimized for its specific function - the connector body for mechanical engagement without damage, the terminal for wire acceptance, and the fabric for electrical conductivity and flexibility.
2Object-affected harmful factors
If simple connector holding is used, then conductive fabric integrity is preserved, but secure electrical connection is not achieved under external strain
Solution Approach 1:
The connector serves as a mediator that provides both mechanical retention and electrical conductivity. It includes conductive elements or pathways that ensure reliable electrical connection between the wire terminal and conductive fabric, while its body structure with teeth or gripping surfaces provides secure mechanical engagement that maintains connection reliability under external strain.
Solution Approach 2:
The connector is designed as a composite structure combining different materials and functions: conductive materials for electrical connection, mechanically strong materials for structural integrity and gripping, and potentially flexible materials to accommodate the conductive fabric's movement. This composite approach ensures both electrical reliability and mechanical security without damaging the conductive fabric.
Data Source
AI summary
Various implementations include a method of connecting wire to conductive fabric. The method includes (1) providing a conductive fabric having a main portion and a protrusion extending along a protrusion central axis from the main portion, the protrusion having a distal edge spaced apart from the main portion along the central axis and side edges that extend between the main portion and the distal edge; (2) placing a wire along at least a portion of the protrusion, the wire having a first end and a second end opposite the first end; (3) folding the distal edge of the protrusion over the wire one or more times to form a folded portion of the protrusion; and (4) after folding the distal edge, securing the folded portion of the protrusion with a securing device.