Electronic Strip Yarn with Nested Protective Sheath
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Solution Overview
Problem
Existing yarns with embedded electronic devices face issues with exposed electrical connections that are compromised by contact with other yarns or external conditions, as previous solutions do not adequately protect these connections.
Innovation Solution
Electronic devices are mounted in sequence on a non-conductive flexible planar support material, which is then slit into strips that can function as yarns, with conductive interconnects extending along the strips, and these strips can be used alone or enclosed in a sleeve, providing protection and versatility for integration into fabrics or other applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connections are exposed on the yarn surface to enable electrical contact, then electrical functionality is achieved, but the connections are compromised by contact with other yarns or external conditions
Solution Approach 1:
The patent applies nesting by placing the electronic device and its electrical connections inside a protective sheath that is itself integrated into the yarn structure. Multiple layers are nested within each other: the core contains the device, which is surrounded by conductive elements, which are then enclosed in a protective sheath, all forming a single yarn unit. This nested structure protects electrical connections while maintaining functionality.
Solution Approach 2:
The patent uses a flexible protective sheath made of thin film material that encloses the electronic device and electrical connections. This sheath acts as a barrier against external conditions while allowing the yarn to remain flexible and integratable into fabrics. The thin film provides protection without adding significant bulk or rigidity.
2Reliability
If electronic devices are mounted on a planar support material and slit into strips, then the devices are protected within the yarn structure, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the continuous planar support material into multiple separate strips, each containing electronic devices. This segmentation allows for standardized manufacturing modules that can be produced efficiently and then assembled into final yarn products. The strip format simplifies handling and integration while maintaining device protection.
Solution Approach 2:
The patent applies preliminary action by pre-mounting electronic devices onto planar support material in a controlled manufacturing environment before the material is slit into strips. This preliminary mounting ensures proper device placement and connection establishment while the material is still in a convenient flat state, making the subsequent slitting and yarn formation processes simpler and more reliable.
Data Source
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AI summary
Electronic devices (4, 24) are mounted in sequence or series along a plurality of laterally spaced discrete lines (10) on a sheet of non- conductive flexible planar support material (50); and the sheet is slit or stripped between said lines to create at least two yarns each in the form of a strip bearing a series of said devices. The width of each strip can be substantially the same as that of the mounted device or devices; normally less than twice that of the device or devices. The support material can be in the form of a continuous length passing through a mounting station (54), and on which series of the electronic devices are mounted in said lines substantially parallel to the direction of passage of the material. The material bearing the devices can be slit into strips directly, or wound onto a roll (64) for subsequent division into strips The material may be formed with lines of weakness (14) to facilitate slitting into strips. The thickness of the support material is normally no more than ΙΟμιη, and with the width of the devices typically being no more than 800nm, a strip bearing the devices can thus be used as a yarn or strip for use in many applications, both functional and decorative, either alone or within a sleeve.