Article and Method of Making the Same
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Solution Overview
Problem
Existing wearable articles with flat electrodes face challenges in achieving robust signal quality and durability due to poor skin contact and motion sensitivity, necessitating an improved method for forming raised conductive regions on textiles.
Innovation Solution
The use of an embossing material applied to a textile body to create a raised, embossed conductive region that retains its shape after heat and pressure application, eliminating the need for dense packing of isolating threads or filler materials and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat electrodes are used in wearable articles, then the manufacturing process is simple, but the signal quality and skin contact are poor
Solution Approach 1:
The patent transitions from two-dimensional flat electrodes to three-dimensional raised electrodes by incorporating embossing material during the knitting process. This dimensional change allows the electrode to protrude from the textile surface, improving skin contact and signal quality while maintaining integration with the textile structure.
Solution Approach 2:
The embossing material is nested within the textile structure during knitting, with the conductive region formed by knitting conductive yarn through the embossing material. This nesting approach integrates the raised profile directly into the textile without requiring separate assembly steps, resolving the contradiction between complexity and performance.
2Shape
If raised conductive regions are formed using dense packing of isolating threads or filler materials, then the raised profile is achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The embossing material is incorporated into the textile structure during the knitting process itself, before the final product is completed. This preliminary action allows the raised profile to be formed as part of the base manufacturing process, eliminating the need for subsequent dense packing operations and improving productivity.
Solution Approach 2:
The patent extracts the embossing function from the final assembly process and integrates it into the knitting process. By using embossing material that is knitted together with the textile, the raised profile is created during base manufacturing rather than requiring separate filler material packing operations afterward.
3Stability of the object's composition
If raised conductive regions are formed without embossing material, then the manufacturing process is simpler, but the raised profile does not retain its shape after washing and use
Solution Approach 1:
The patent uses composite materials by combining embossing material with conductive yarn during the knitting process. The embossing material provides structural support for the raised profile, while the conductive yarn provides electrical conductivity. This composite approach ensures profile retention through washing and use while maintaining integration with the textile structure.
Solution Approach 2:
The embossing material is strategically placed only in the regions where raised profiles are needed, rather than throughout the entire textile. This local quality approach provides profile retention where necessary while minimizing additional material complexity and maintaining flexibility in other areas of the textile.
4Reliability
If additional waterproofing steps are added to protect the conductive region, then the durability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The embossing material serves multiple functions simultaneously: it provides the raised profile structure, supports the conductive region, and acts as a waterproofing barrier. This multi-functionality eliminates the need for separate waterproofing steps, improving durability while keeping the manufacturing process simple.
Solution Approach 2:
The patent merges the structural support function and waterproofing function into a single component - the embossing material. By combining these functions that would traditionally require separate materials and assembly steps, the manufacturing process remains simple while achieving improved durability and profile retention.
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 enhances signal contact with the skin, improves durability against motion, and simplifies the manufacturing process by integrating embossing techniques into existing textile production methods, while providing waterproofing properties without additional steps.
Implementation Method 1
The embossing material may have a melting point of between 50 degrees Centigrade and 250 degrees Centigrade
Implementation Method 2
The embossing material is a material that can be moulded to a desired shape and bonded to the textile body by the application of a stimulus
Data Source
AI summary
The article (100) comprises a textile body (101), a conductive region (103) and an embossing material (105). The embossing material 105 causes the conductive region (103) to adopt and retain a raised, embossed, profile (107) that projects outwardly from a surface (102) of the textile body (101). The method comprises applying heat and/or pressure to the article (100) to cause the article (100) to adopt the embossed profile (107). The raised, embossed, profile (107) is retained upon release of the applied heat and/or pressure as the embossing material (105) has bonded to the textile body (101) due to the application of heat and/or pressure.