E-Textile Seam Ultrasonic Welding for Conductor Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrically active textiles face challenges in comfort, connectivity, and manufacturing efficiency due to conductive fibers not feeling as comfortable as regular fibers, and requiring manual operations like stripping insulation and soldering, with limited cooperation between textile and electronic component manufacturers.
Innovation Solution
The method involves weaving conventional yarn wrapped with small insulated wires, using ultrasonic welding to connect conductive cores at seams, ensuring durable and economical electrical and mechanical connections without stripping insulation, and determining conductor intersections beforehand to avoid unintended connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive fibers are used to create electrically active textiles, then electrical connectivity is achieved, but comfort deteriorates because the conductive fibers do not feel as comfortable as regular textile fibers
Solution Approach 1:
The patent combines regular textile fibers with conductive fibers to create a composite material that maintains the comfort properties of natural fibers while incorporating electrical conductivity. The conductive fibers are integrated into the textile structure rather than replacing the entire fabric, allowing the material to exhibit both mechanical comfort and electrical functionality.
2Ease of manufacture
If conductive fibers run in one direction to simplify manufacturing, then ease of manufacture improves, but adaptability deteriorates because electrical components on opposite sides cannot be easily connected
Solution Approach 1:
The patent extracts the electrical connection function from the fiber orientation constraint by introducing separate connection mechanisms at seams and intersections. Rather than relying solely on continuous fiber runs, the system uses localized connection points that can adapt to different component placements while maintaining manufacturing simplicity.
Solution Approach 2:
The textile system is designed with multi-functional capabilities where the same fabric structure can support various electrical component configurations. The seam connections and intersection points serve as universal connection nodes that can connect different orientations and types of electrical components without requiring changes to the base fabric structure.
3Manufacturing precision
If manual operations like stripping insulation and soldering are used to connect conductive fibers, then connection precision improves, but productivity deteriorates due to numerous manual operations required
Solution Approach 1:
The patent replaces manual mechanical operations (stripping, soldering) with automated processes. The system uses specialized weaving or knitting machines that can automatically position and connect conductive fibers during fabric production, eliminating the need for subsequent manual intervention while maintaining connection precision through programmed control.
Solution Approach 2:
The conductive fibers are pre-positioned and pre-connected during the textile manufacturing process itself, rather than requiring post-production assembly. The fabric is produced with the electrical connection structure already integrated, allowing connections to be made as part of the standard manufacturing workflow without requiring separate manual operations.
4Reliability
If conductive fibers are cut to terminate signal lines, then unwanted connections are avoided, but device complexity increases due to numerous manual operations
Solution Approach 1:
The textile structure itself provides the signal termination function through its inherent design features. The fabric pattern, seam locations, and fiber routing are configured to naturally terminate signal lines at appropriate points without requiring additional manual intervention or complex termination components. The structure serves its own termination function through proper design.
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 results in a more comfortable and versatile electronic fabric with efficient electrical connectivity, reducing manual operations and enabling the development of realistic and economical e-textile devices.
Implementation Method 1
During ultrasonic welding at a seam, for example, or to connect warp conductors to weft conductors, the plastic insulation of the wires melt, the polymer material (e.g., nylon) in the yarn melts, and the conductive cores of the wires come into contact with each other.
Data Source
AI summary
A method of making articles from electrically active textiles. First and second fabric pieces include conductors therein. A seam is established between the first and second fabric pieces. A determination is made, at the seam, based on one or more predetermined factors, which conductors of the first fabric piece intersect or overlap with which conductors of the second fabric piece. At the seam, an electrical and mechanical connection is formed between select conductors of the first fabric piece and select conductors of the second fabric piece.