Conductive Strands with Polymer Core Recesses
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Solution Overview
Problem
Forming conductive structures from conductive strands in fabric-based items is challenging due to the risk of metal coating abrasion and failure when the fabric is bent, leading to reliability issues like unexpected open circuits.
Innovation Solution
The use of elongated polymer cores with recesses to enhance the retention of metal coatings, combined with intermediate layers and additional fabrication techniques such as electrochemical deposition, to form robust and durable conductive strands that can withstand bending stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If polymer strands covered with metal coatings are used in place of solid wire strands, then flexibility and fabric integration are improved, but the metal coating may be abraded or fail due to modulus of elasticity mismatch during fabric bending
Solution Approach 1:
The patent applies local quality by creating recesses in specific locations on the polymer core surface to locally enhance metal coating retention. The recesses are strategically positioned to provide anchoring points for the metal coating, ensuring that the coating remains attached during fabric bending and flexing operations without requiring changes to the entire strand structure.
Solution Approach 2:
The patent employs composite materials by combining polymer core material with metal coating material in a layered structure. The polymer core provides flexibility and fabric integration, while the metal coating provides electrical conductivity. The composite structure with recesses creates a synergistic effect where the polymer supports the metal coating and the metal coating enhances the functional properties of the polymer strand.
2Reliability
If metal coatings are applied to polymer strands for conductivity, then electrical signal transmission is enabled, but the metal coating may fracture due to bending stresses from fabric flexing
Solution Approach 1:
The patent applies beforehand cushioning by creating recesses in the polymer core before applying the metal coating. These recesses serve as pre-prepared anchoring structures that cushion and absorb the stress generated during fabric bending, preventing the metal coating from fracturing. The recesses are formed in advance to ensure the metal coating has secure attachment points before any bending stresses occur.
3Reliability
If solid wires are used for conductive structures, then electrical conductivity is reliable, but the wires experience large amounts of stress when the fabric is bent
Solution Approach 1:
The patent applies flexible shells and thin films by using a polymer core with metal coating instead of traditional solid wire structures. The polymer core acts as a flexible shell that can bend and flex with the fabric, significantly reducing bending stresses compared to rigid solid wires. The thin metal coating layer provides electrical conductivity while conforming to the flexible polymer substrate, enabling the conductive structure to maintain reliability under fabric bending conditions.
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
The solution effectively retains the metal coating on the polymer core, reducing the risk of fractures and ensuring reliable electrical conductivity even under stress, enhancing the mechanical robustness and electrical performance of fabric-based items.
Implementation Method 1
A polymer core may be provided with recesses to help retain subsequently deposited layers such as a metal coating layer. The recesses may be grooves that extend along the longitudinal axis of the core. When a coating is formed on the core, the metal of the coating may extend into the recesses.
Implementation Method 2
Metal coatings may be deposited using electrochemical deposition techniques (e.g., electroless deposition).
Data Source
AI summary
Strands of material may be intertwined using weaving techniques, knitting techniques, non-woven or entanglement techniques, or braiding techniques. Fabric that is formed from the strands of material may be used in forming a fabric-based item. The fabric based item may include electrical components. The strands may include conductive strands that form signal paths. The signal paths can carry electrical signals associated with operation of the electrical components. Each strand may have an elongated core and a coating. Strands may also include intermediate layers between the cores and coatings. The cores, intermediate layers, and coatings may be formed from polymer without conductive filler, polymer with conductive filler, and/or metal. A polymer core may be provided with recesses to help retain subsequently deposited layers such as a metal coating layer. The recesses may be grooves that extend along the longitudinal axis of the core.