Conductive Metal Composite Yarn Yield Strength
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Solution Overview
Problem
Conventional electrically conductive metal composite yarns have weak yield strength, leading to non-uniform electric resistance in embroidered circuits due to stretching or cutting during the embroidery process, and face challenges in producing uniform thickness and maintaining electrical contact among conductive yarns.
Innovation Solution
A method involving wrapping a conductive yarn around a yarn, twisting it to form a covered yarn, and then wrapping another yarn around multiple strands of the twisted covered yarn in the opposite direction to increase yield strength, resulting in a reinforced plied-yarn with controlled twists per meter to enhance tensile strength and prevent stretching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of twists per meter is increased to strengthen the electrically conductive metal composite yarn, then the strength increases, but torque occurs causing feeding interruption and continuous elongation of the metal filament
Solution Approach 1:
The patent optimizes the twist parameters by controlling the number of twists per meter within a specific range (20-300 TM for covering, 200-1000 TM for additional twisting) and specifies twist direction relationships. This parameter optimization achieves the balance between strength enhancement and preventing excessive torque that would cause feeding interruption.
Solution Approach 2:
The patent creates a composite structure consisting of conductive yarn wrapped around core yarn, with multiple layers of covering and twisting. This composite construction distributes mechanical stress and prevents single-point failure, maintaining feeding continuity while achieving required strength.
2Ease of manufacture
If the yield strength of the conductive yarn is weak, then the manufacturing process is simpler, but the conductive yarn stretches or is cut during embroidery causing non-uniform electric resistance
Solution Approach 1:
The patent performs preliminary strengthening actions during the yarn manufacturing process itself, including covering the conductive yarn with protective yarn and applying controlled twisting before the embroidery process. This preliminary reinforcement prevents stretching and cutting during subsequent embroidery operations, ensuring uniform electric resistance without complicating the overall manufacturing workflow.
Solution Approach 2:
The patent applies protective covering yarn around the conductive yarn to cushion and protect it from mechanical damage during handling and embroidery. This protective layer acts as a buffer that prevents direct stress concentration on the conductive filament, preventing cutting and excessive stretching.
3Reliability
If a metal filament yarn is used to cover a general yarn, then the electrically conductive properties are achieved, but it is difficult to produce uniform thickness and maintain appearance
Solution Approach 1:
The patent assigns different functional qualities to different parts of the composite yarn structure. The core yarn provides structural support and uniformity, while the wrapped conductive yarn provides electrical conductivity. This local differentiation of functions allows each component to optimize its own properties without compromising the other.
Solution Approach 2:
The patent specifies precise parameter ranges for the covering process, including the number of twists per meter (20-300 TM) and the denier range of core yarn (20-500 denier). These controlled parameters ensure uniform thickness and appearance while maintaining the electrically conductive properties of the metal filament yarn.
Data Source
AI summary
Provided are a method of producing an electrically conductive metal composite yarn applicable to a smart textile in which electrical, electronic and IT technologies are combined with an electronic circuit technology using fiber, an electrically conductive metal composite yarn produced by the method, and an embroidered circuit produced using the electrically conductive metal composite yarn, the method including: a first process of producing a covered yarn by wrapping a conductive yarn around a surface of a yarn; a second process of producing a twisted covered-yarn by additionally twisting the covered yarn produced through the first process; and a third process of producing a reinforced plied-yarn by wrapping a yarn around a surface of multiple strands of the twisted covered-yarn in a covered state to increase yield strength of the conductive yarn.