Elastomeric Circuit Cable Structure for Continuous Flexing
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Solution Overview
Problem
Wires and cables fracture due to continuous flexing, leading to reduced conductivity and potential failure.
Innovation Solution
Development of elastomeric and flexible cables with conductive cabling and integrated circuits, protected by a PTFE tape and jacket, allowing for stretchability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal wire is used for continuous flexing applications, then initial conductivity is good, but the wire fractures and conductivity decreases over time
Solution Approach 1:
The patent changes the material parameter from traditional metal wire to elastomeric material with conductive properties. This fundamental material parameter change allows the cable to maintain flexibility and conductivity simultaneously, resolving the contradiction between initial conductivity and durability under continuous flexing conditions.
Solution Approach 2:
The patent uses composite construction by wrapping conductive cabling around an elastomeric substrate and protecting it with PTFE tape and jacket. This composite structure combines the flexibility of elastomer with the conductivity of metal cabling, achieving both good initial conductivity and long-term reliability under flexing.
2Adaptability or versatility
If the cable is made flexible and stretchable, then adaptability to wearable applications is improved, but structural integrity may compromise
Solution Approach 1:
The patent employs flexible PTFE tape and jacket as protective shells that wrap around the conductive cabling. These flexible protective layers maintain the cable's stretchability and adaptability for wearable applications while providing the structural integrity needed to prevent damage during flexing and stretching.
Solution Approach 2:
The patent applies protective PTFE wrapping and jacketing beforehand to cushion and protect the conductive cabling from mechanical stress. This preemptive protection allows the cable to be made flexible and stretchable for wearable applications without compromising the underlying structural integrity of the conductive elements.
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 cables maintain conductivity and integrity under flexing, enabling applications in wearable electronics and harsh environments without breaking.
Implementation Method 1
The cable may then be wrapped with a Polytetrafluoroethylene (PTFE) tape that can be heated to shrink about the cable for protection of the underlying circuitry
Implementation Method 2
the cables disclosed may include an elastomeric non-conductive core or substrate configured from a polymer. This may allow the cable to stretch and bend more easily
Data Source
AI summary
Systems and methods presented herein provide for elastomeric and flexible cables. In one embodiment, the cables are configured with elastomeric cabling and circuitry. For example, a flexible circuit line (or lines) may be wrapped about an extruded elastomeric substrate (e.g., a polymer). Integrated circuits (e.g., sensors, accelerometers, light emitting diodes, controllers, microprocessors, etc.) may be disposed at various points along the circuit line(s). The cable may then be wrapped with a Polytetrafluoroethylene (PTFE) tape than can be heated to shrink about the cable for protection of the underlying circuitry. Then, the cable may be surrounded with a layer of polymer and extruded to form an elastomeric and flexible cable.