Flexible Garment Heating Element via Mask Etching
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Solution Overview
Problem
Existing garment heating systems are not efficiently integrated into standard textile production processes, compromising the fashion and comfort aspects of heated garments.
Innovation Solution
A system comprising a heated garment with a textile-based heating element doped with conductive particulate, integrated into a garment insert that can be seamlessly incorporated into standard garment manufacturing processes, using a power module and connectors that are flexible and easy to assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating elements are integrated into garments using specialized manufacturing processes, then heating functionality is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The heating system is divided into separate modular components: a garment insert containing the heating element, and a power module. This segmentation allows each component to be manufactured independently using standard textile processes, then assembled together, reducing overall manufacturing complexity while maintaining heating functionality.
Solution Approach 2:
The garment insert is designed to be universally applicable to multiple garment types and styles. By creating a standardized insert that can be integrated into various garments using conventional textile manufacturing methods, the system achieves heating functionality without requiring specialized production lines for each garment type.
2Reliability
If heating elements are integrated into garments, then heating functionality is achieved, but the garment's fashion and comfort aspects are compromised
Solution Approach 1:
The heating element is constructed as a thin, flexible textile-based structure that can be seamlessly integrated into garment layers. This thin-film approach minimizes the physical profile of the heating component, preserving the garment's drape, comfort, and aesthetic appearance while maintaining effective heating functionality.
Solution Approach 2:
The garment insert acts as an intermediary layer between the garment's exterior and interior, housing the heating element in a way that is invisible from the outside. This mediator approach allows the heating functionality to be embedded without affecting the garment's external fashion appearance or internal comfort characteristics.
3Ease of manufacture
If power modules and connectors are made flexible for easy assembly, then ease of manufacture is improved, but connection reliability may be compromised
Solution Approach 1:
The connectors and power module are designed with flexible, dynamic connection mechanisms that can accommodate movement and deformation without compromising electrical contact. This dynamic design allows the connectors to maintain reliable connections even when subjected to the flexibility and movement inherent in wearable garments, while remaining easy to assemble.
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 system effectively heats the garment while maintaining its fashion and comfort aspects, as it is integrated using standard textile production methods, ensuring minimal disruption to the garment's appearance and feel.
Implementation Method 1
textile-based heating element doped with conductive particulate
Implementation Method 2
textile-based heating element doped with conductive particulate
Data Source
AI summary
One variation of a method for fabricating a garment includes: applying a first mask to a first side of a fabric substrate coated with a conductive material; applying a second mask—mirrored image of the first mask—to a second side of the fabric substrate opposite the first side; applying an etchant to the fabric substrate to remove conductive material outside of the first mask; arranging a conductive interface pad of a component carrier over an electrode defined by remaining conductive material on the fabric substrate, the component carrier including a flexible substrate and a rigid electrical component mounted to the flexible substrate, the conductive interface pad extending from a terminal of the rigid electrical component across a region of the flexible substrate; mechanically fastening the component carrier to the fabric substrate to form a garment insert including an electrical circuit; and incorporating the garment insert into the garment.