Fabric Seam Electrical Component Integration via Segmentation
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Solution Overview
Problem
Incorporating electrical components into fabric items is challenging due to the flexibility of fabric, which can cause signal paths to be damaged or components to become dislodged when the fabric is bent or stretched.
Innovation Solution
Interlacing equipment with individually adjustable components is used to insert and embed electrical components into the fabric during its creation, creating gaps between fabric portions where conductive strands can be soldered or attached to the components, ensuring secure and durable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are mounted on flexible fabric, then enhanced functionality is provided, but signal paths may be damaged or components may become dislodged when fabric is bent or stretched
Solution Approach 1:
The fabric is divided into separate layers (first fabric layer and second fabric layer) with the electrical component positioned between them. This segmentation allows the component to be mechanically isolated from the fabric's bending and stretching forces, preventing dislodgement while maintaining electrical connectivity through the layered structure.
Solution Approach 2:
The electrical component is nested between two fabric layers, creating a protected sandwich structure. This nesting approach embeds the component within the fabric assembly rather than mounting it on the surface, providing mechanical protection while maintaining integration with the flexible substrate.
2Reliability
If electrical components are embedded in fabric during creation, then secure connections are achieved, but interlacing equipment complexity increases
Solution Approach 1:
Gaps are pre-formed in the fabric layers at specific locations before the interlacing operation is completed. These preliminary gaps are positioned to accommodate electrical components, allowing for straightforward component insertion and integration without requiring complex real-time adjustments during the fabric creation process.
Solution Approach 2:
Conductive strands serve as intermediaries between the electrical components and the fabric structure. These strands are threaded through the pre-formed gaps and connected to component terminals, providing a simple mechanical and electrical connection method that bridges the component and fabric without requiring complex integration mechanisms.
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, maintaining mechanical robustness and electrical conductivity even when the fabric is bent or stretched, enabling the creation of functional items like wearable technology and smart textiles.
Implementation Method 1
An electrical component may be coupled to the conductive strand and may have a groove in which the conductive strand is soldered or otherwise attached.
Data Source
AI summary
One or more electrical components may be incorporated into a fabric seam. The fabric seam may join two pieces of material in a fabric item or may form the border of a fabric item. The fabric seam may include first and second fabric portions with one or more conductive strands extending between the first and second fabric portions. An electrical component may be coupled to the conductive strand. The fabric seam may have one or more side pockets for capturing the edge of a material such as a piece of fabric. The fabric seam may have gaps that allow conductive strands within the fabric seam to branch off in different directions. Openings may be incorporated in the fabric seam to allow air or light to pass through and/or to form a window for an electrical component in the fabric seam.