Multi-Material Fiber Bonding for Durable Textile Electronics

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Solution Overview

Problem

Conventional multi-material fibers lack the reliability and durability to withstand mechanical and environmental stresses typical of textile use cases, such as bending, washing, and exposure to sunlight and temperature changes.

Innovation Solution

A method of manufacturing multi-material fibers by positioning electrically-connectable devices within pockets in a preform material, and drawing the fiber to form metallurgical bonds between electrical conductors and electrodes, ensuring robust connections and improved mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional multi-material fibers are manufactured using standard thermoplastics and cross-sectional architectures, then the manufacturing process is simple, but the fibers lack adequate reliability and cannot withstand mechanical and environmental abuse

Engineering Contradiction:

Improvefiber reliabilityVSAvoidfiber structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The fiber is divided into multiple functional segments including a core region containing electrical conductors and devices, and a cladding region providing mechanical protection. This segmentation allows each region to be optimized for its specific function while collectively providing both reliability and manageable complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fiber employs composite materials combining thermoplastic cladding materials with metallic electrical conductors and semiconductor devices. This composite approach enables the fiber to simultaneously achieve mechanical durability from the thermoplastic and electrical functionality from the metallic and semiconductor components

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If semiconductor devices are incorporated at the preform fabrication stage, then device location control is limited, but the manufacturing process is simplified

Engineering Contradiction:

Improvedevice location controlVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Conduits for electrical conductors are pre-formed within the preform structure before drawing. This preliminary action ensures precise conductor positioning is achieved during the drawing process itself, eliminating the need for post-drawing positioning operations and maintaining manufacturing simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical positioning systems with a field-based approach where electrical conductors are positioned through electromagnetic field guidance during the drawing process, achieving high precision without adding mechanical complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the number of connections between multi-material fibers is increased, then more functions are achieved, but manufacturing yields decrease

Engineering Contradiction:

Improvetextile functionalityVSAvoidmanufacturing yield

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The fiber design incorporates universal connection interfaces and standardized conductor configurations that can be used across multiple fiber interconnections. This universality allows the same basic fiber structure to achieve multiple functions through different connection topologies, increasing versatility without requiring complex variations that would reduce manufacturing yield

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method enhances the reliability and durability of multi-material fibers, enabling them to withstand significant mechanical and environmental abuse while maintaining electrical connectivity.

Implementation Method 1

a metallurgical bond may be formed between the first electrical conductor and the first electrode while drawing the multi-material fiber

Methodology Applied

Scientific EffectMetallurgical bond: Welding

Data Source

PatentUS20250027234A1Multi-material fibers and methods of manufacturing the same

Publication Date: 2025.01.23 ADVANCED FUNCTIONAL FABRICS OF AMERICA INC

AI summary

Methods of manufacturing multi-material fibers having one or more electrically-connectable devices disposed therein are described. In certain instances, the methods include the steps of: positioning the electrically-connectable device(s) within a corresponding pocket provided in a preform material; positioning a first electrical conductor longitudinally within a first conduit provided in the preform material; and drawing the multi-material fiber by causing the preform material to flow, such that the first electrical conductor extends within the multi-material fiber along a longitudinal axis thereof and makes an electrical contact with a first electrode located on each electrically-connectable device. A metallurgical bond may be formed between the first electrical conductor and the first electrode while drawing the multi-material fiber and/or, after drawing the multi-material fiber, the first electrical conductor may be located substantially along a neutral axis of the multi-material fiber.