Conductive Yarn Interconnects for Flexible Textile Electronics
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Solution Overview
Problem
Existing methods for connecting electronic components to flexible fabrics, such as textiles, are limited in their ability to supply higher currents due to the low electrical conductivity of electrically conductive yarns used for contacting, resulting in significant power losses, and conventional conductors cannot be directly integrated into the fabric.
Innovation Solution
The method involves using a conventional conductor with higher conductivity, such as a copper wire, that is partially embedded or attached to the fabric and connected to the electronic component via an electrically conductive yarn using embroidery or sewing, minimizing power losses by maintaining the conductor's high conductivity while allowing integration without soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If electrically conductive yarns are used for contacting electronic components to flexible fabrics, then the component can be mechanically fastened and electrically connected, but the electrical conductivity is low resulting in significant power losses
Solution Approach 1:
The electrical connection system is divided into two functional segments: a conventional conductor segment for low-resistance current transport and an electrically conductive yarn segment for mechanical integration and short-distance electrical connection. This segmentation allows each component to optimize its specific function, resolving the contradiction between energy efficiency and manufacturing ease.
Solution Approach 2:
The electrically conductive yarn acts as an intermediary element that bridges the conventional conductor and the electronic component. It transfers both mechanical fastening function and electrical connection function, enabling the system to achieve both low power losses through the conventional conductor and easy integration through the yarn's sewing/embroidery capability.
2Loss of energy
If conventional conductors are used for electrical connection, then higher currents can be supplied with reduced power losses, but the conductor cannot be directly integrated into the fabric without soldering
Solution Approach 1:
The electrically conductive yarn serves as a mediator that eliminates the need for soldering by providing a mechanical fastening method (sewing or embroidery) that simultaneously creates electrical connection. This intermediary component allows conventional conductors to be integrated into flexible fabrics using simple textile techniques rather than complex metallurgical processes.
Solution Approach 2:
The patent replaces the mechanical soldering process with a textile-based mechanical fastening system. Instead of using heat and metallurgy to join conductor to fabric, the system uses sewing or embroidery stitches to mechanically secure the conventional conductor while maintaining electrical continuity, thereby reducing device complexity.
3Strength
If electrically conductive yarns are used for contacting, then mechanical fastening is achieved, but the electrical conductivity is insufficient for higher current supplies
Solution Approach 1:
The system segments the electrical connection pathway into a high-reliability conventional conductor portion for main current transport and a yarn portion for mechanical attachment and localized connection. This segmentation allows the conventional conductor to ensure electrical connection reliability for higher currents while the yarn provides the necessary mechanical fastening strength.
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 enables efficient electrical connection and mechanical fastening of electronic components to flexible fabrics, reducing power losses and allowing for the integration of higher current supplies while maintaining industrial simplicity and cost-effectiveness.
Implementation Method 1
The at least one contacting section is connected to the first conductor by means of an electrically conductive yarn
Implementation Method 2
The component is embroidered onto the textile fabric using an embroidery machine
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for electrically connecting an electronic component (4) on a flat flexible structure (1). The flat structure (1) forms or comprises a textile, a woven fabric, a nonwoven, or a knitted fabric, and a first conductor (2) is placed on or in the flat structure (1), said first conductor (2) having a first conductivity, and the electronic component (4) is secured on the flat structure (1), wherein the electronic component (4) has at least one contacting section (9) for establishing electronic contact, and the at least one contacting section (9) is connected to the first conductor (2) by means of an electrically conductive yarn (10). The conductive yarn (10) has a second conductivity, said second conductivity preferably being lower than the first conductivity.