Conductive Wire Flat Seam for Clothing
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Solution Overview
Problem
Existing methods for incorporating conductive wires into clothing are delicate, aesthetically degrading, and prone to mechanical stress and microshorts, particularly when attempting to transmit significant electrical power or create localized electrical circuits.
Innovation Solution
The use of a flat seam with a sinusoidal connecting wire layout, incorporating multiple edging and connecting wires, allows for the integration of conductive wires without adding thickness, reducing mechanical stress and the risk of microshorts, while enabling the transmission of electrical power and heat through Joule effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive wires are fixed on clothing using non-conductive wires or seams, then the conductive wires can be attached to transmit electrical current, but the mechanical stresses concentrate on the wire attachment points increasing the risk of microshorts
Solution Approach 1:
The conductive wire is divided into multiple segments separated by insulating sections. This segmentation distributes mechanical stresses along the wire rather than concentrating them at single attachment points, reducing the risk of microshorts while maintaining electrical connectivity where needed.
Solution Approach 2:
Insulating sections are introduced as intermediary elements between conductive wire segments. These insulating sections act as mediators that protect against microshorts by electrically isolating adjacent conductive segments while allowing the wire to flex and accommodate mechanical stresses.
2Ease of manufacture
If conductive wires are laid on the surface of clothing, then the wires can be easily attached, but the aesthetic aspect of the clothing is degraded
Solution Approach 1:
The conductive wire is nested within the seam structure of the clothing rather than being laid on the surface. The wire is incorporated into the seam layers, making it invisible from the exterior while maintaining ease of attachment during the seam construction process.
Solution Approach 2:
The seam structure acts as a flexible shell that encloses and protects the conductive wire. This thin film-like seam structure allows the wire to be hidden within the clothing construction while maintaining the flexibility and aesthetic appearance of the garment.
3Reliability
If metal wires are inserted into the thickness of fabric to form conductive network, then electrostatic charges can be conducted, but the wires are not suitable for transmitting significant electrical current and have high risk of microshorts
Solution Approach 1:
The conductive wire is extracted from the fabric thickness and positioned within the seam structure on the surface. This extraction allows the use of thicker, more current-capable wires that are less prone to microshorts, while the seam provides the necessary protection and routing.
Solution Approach 2:
The solution combines conductive wire with insulating sections and seam structures to create a composite system. This composite approach allows the conductive elements to transmit significant current while the insulating components prevent microshorts, achieving both reliability and safety.
4Reliability
If a large number of overlapping metal wires are used to conduct electrostatic charges, then electrostatic discharge is improved, but the structure is not suitable for producing localized and isolated electrical circuits
Solution Approach 1:
The conductive wire is segmented into discrete sections separated by insulating parts. This segmentation enables the creation of localized and isolated electrical circuits at specific positions along the wire, providing adaptability for different applications while maintaining electrostatic discharge capability through the distributed structure.
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 allows for the creation of aesthetically intact clothing with conductive networks capable of transmitting several watts of electrical power, reducing the risk of microshorts and enabling flexible, insulated electrical circuits for various applications, including winter sports and physiological analysis.
Implementation Method 1
at least one conductive wire suitable for transmitting an electric current
Implementation Method 2
suitable for transmitting an electric current and/or to heat said clothing by Joule effect
Data Source
AI summary
An article of clothing having at least one conductive wire suitable for transmitting an electric current and at least one flat seam is disclosed. The seam includes at least two substantially parallel edging wires; at least one connecting wire disposed in a flat and serpentine manner between said edging wires; the connecting wire having bends connected alternately to the edging wires; the connecting wire corresponding to the at least one metal wire; and at least one other connecting wire extending in a separate plane from the connecting wire disposed in a flat manner.