Conductive Yarn Stability via Composite Filament Structure
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Solution Overview
Problem
Existing electrically conductive yarns lack stability and uniform resistance, leading to unreliable heat emission and comfort issues in products like actively heated clothing, as they are prone to resistance variations due to contact point shifts and material degradation.
Innovation Solution
A composite yarn is created by twisting textile fibers with an electrically conductive filament yarn that has a core of multiple filaments and a surface layer of conductive material, providing stable resistance and flexibility, allowing for predictable conductivity and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If yarns consisting of a mix of natural and/or synthetic fibers and electrically conductive fibers are used, then the yarn can conduct electricity, but the resistance is unstable and varies over time
Solution Approach 1:
The patent uses a composite yarn structure combining non-conductive textile fibers with conductive fibers (such as metal or conductive polymer-coated fibers) to create a yarn that maintains stable electrical resistance. The composite structure ensures consistent contact between conductive fibers, preventing resistance variations over time while maintaining textile properties.
Solution Approach 2:
The patent controls the physical and chemical parameters of the conductive fibers, including their diameter, conductivity, and surface properties, to optimize resistance stability. By carefully selecting and controlling these parameters, the yarn achieves reliable and consistent electrical resistance for heating applications.
2Strength
If the yarn is made strong and abrasion resistant, then the product becomes durable, but the yarn may become less flexible and harder to handle in knitting machines
Solution Approach 1:
The patent applies different properties to different parts of the yarn structure. The core provides strength and durability, while the outer surface maintains flexibility and softness for comfortable wear. This local differentiation allows the yarn to be both strong and easy to handle in textile machinery.
Solution Approach 2:
By combining fibers with different properties in a composite structure, the yarn achieves both high strength for durability and sufficient flexibility for machine handling. The non-conductive textile fibers provide structural integrity while the conductive fibers are distributed to maintain electrical properties without compromising flexibility.
3Reliability
If the yarn has suitable resistance for heat emission, then heat can be controlled reliably, but the yarn may become less comfortable against the body
Solution Approach 1:
The conductive fibers are distributed throughout the yarn structure rather than concentrated on the surface, allowing the outer surface to remain soft and comfortable against the skin while the internal structure provides the necessary electrical conductivity for reliable heat emission control.
4Reliability
If filament yarn with metal filaments is used for conductivity, then electrical current can be conducted, but the yarn cannot be handled by conventional textile machines and lacks user comfort
Solution Approach 1:
The patent combines conventional textile fibers with conductive fibers in a composite yarn that maintains the handling properties and machine compatibility of traditional textiles while providing reliable electrical conductivity. The conductive fibers are integrated into the yarn structure rather than used as separate metal filaments, enabling compatibility with conventional textile machinery and maintaining user comfort.
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 achieves stable and reliable heat emission, improved durability, and enhanced comfort by stabilizing conductivity and maintaining performance over time, even under mechanical stress.
Implementation Method 1
an electrically conductive yarn, i.e. a yarn being capable of conducting electrical current
Implementation Method 2
heating elements that generates heat as a supplement to the user's body heat
Data Source
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Figure 8
AI summary
An electrically conductive yarn comprises a fiber yarn (1) which includes textile fibers (2) and electrically conductive fibers (3). The fiber yarn is twisted with a filament yarn (10) which is electrically conductive at least at its surface. The electrically conductive yarn can be used in different products in order to, for instance, create areas for heat emission and conductors for current to and from such areas and other components.