Interposer Recesses for Robust Electrical Connections in Fabric
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Solution Overview
Problem
Incorporating electrical components into fabric items is challenging due to the flexibility of fabric, which can damage signal paths and dislodge components when bent or stretched, making it difficult to create robust connections between electrical components and fabric.
Innovation Solution
The use of conductive yarns forming signal paths within fabric, with electrical components embedded in pockets and electrically coupled to these paths through interposers, which are either rigid or flexible printed circuit substrate layers, and secured with conductive strands threaded through recesses or trenches in the components or protective covers, using thermoplastic material to create a secure and sealed connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are directly mounted on fabric, then the fabric item gains enhanced functionality, but the connection becomes fragile and components may become dislodged when fabric is bent or stretched
Solution Approach 1:
The patent introduces an interposer as an intermediary component between the electrical component and the fabric. The interposer provides a stable mounting platform with recesses that receive conductive strands, acting as a mediator that isolates the electrical component from the mechanical stress of fabric movement while maintaining electrical connectivity through the conductive strands.
Solution Approach 2:
The patent segments the connection system into distinct functional elements: the electrical component, the interposer, the conductive strands, and the fabric. This segmentation allows each element to perform its specific function optimally - the interposer handles mechanical stability, the conductive strands handle electrical connectivity, and the fabric provides flexibility, resolving the contradiction between functionality and connection stability.
2Ease of operation
If fabric is made flexible for comfort and wearability, then user comfort improves, but signal paths and electrical connections are damaged when fabric is bent or stretched
Solution Approach 1:
The patent employs flexible printed circuit substrate layers as part of the interposer structure. These flexible circuit layers can bend and flex with the fabric while maintaining electrical connectivity, allowing the signal paths to remain intact during fabric movement. The flexible nature of these circuit layers matches the fabric's flexibility while preserving signal integrity.
Solution Approach 2:
The interposer acts as a mediator between the rigid electrical components and the flexible fabric. It provides a transition zone that can accommodate fabric movement through flexing circuit layers while maintaining stable electrical connections, thus preserving signal path integrity during bending and stretching.
3Reliability
If conductive strands are threaded through recesses in the interposer for secure connection, then connection robustness improves, but the manufacturing process becomes more complex
Solution Approach 1:
The recesses are pre-formed in the interposer during its manufacturing process, before the conductive strands are attached. This preliminary action simplifies the overall manufacturing by integrating the recess formation into the interposer fabrication, reducing the need for separate complex assembly steps to create the connection structures.
Solution Approach 2:
The conductive strands are threaded through recesses that are formed within the interposer structure. This nested arrangement, where the recesses are integrated into the interposer body, creates a compact and robust connection system that reduces the overall complexity compared to external mounting structures.
4Reliability
If thermoplastic material is used to seal the connection between conductive strands and bond pads, then protection from mechanical damage and environmental contaminants improves, but the manufacturing process requires additional heating steps
Solution Approach 1:
The thermoplastic material undergoes a phase transition from solid to liquid when heated, allowing it to flow and seal around the conductive strands and bond pads. Upon cooling, it returns to solid state, providing a protective seal. This phase transition mechanism enables effective sealing through a relatively simple thermal process integrated into the manufacturing workflow.
Solution Approach 2:
The thermoplastic material acts as an intermediary sealing substance that bonds the conductive strands to the bond pads while protecting the connection. It provides a protective interface that shields the electrical connection from mechanical damage and environmental contaminants, justifying the additional heating step in the manufacturing process.
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 method allows for the reliable integration of electrical components into fabric items, ensuring robust connections that withstand bending and stretching, while providing a secure and protected electrical pathway.
Implementation Method 1
Heat may be applied to reflow solder in the trench and melt the thermoplastic material
Implementation Method 2
Heat may be applied to reflow solder in the trench and melt the thermoplastic material
Implementation Method 3
Heat may be applied to reflow solder in the trench and melt the thermoplastic material. Once cooled and hardened, the solder may form a secure electrical connection
Data Source
AI summary
An item may include fabric having insulating and conductive yarns or other strands of material. The conductive strands may form signal paths. Electrical components can be mounted to the fabric. Each electrical component may have an electrical device such as a semiconductor die that is mounted on an interposer substrate. The interposer may have contacts that are soldered to the conductive strands. A protective cover may encapsulate portions of the electrical component. To create a robust connection between the electrical component and the fabric, the conductive strands may be threaded through recesses in the electrical component. The recesses may be formed in the interposer or may be formed in a protective cover on the interposer. Conductive material in the recess may be used to electrically and/or mechanically connect the conductive strand to a bond pad in the recess. Thermoplastic material may be used to seal the solder joint.