Fluidic Wire Connectors With Liquid Metal Reservoir Sealing
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Solution Overview
Problem
Conventional solid metal wires face challenges in deformability and durability, especially in applications where mechanical stress or deformation is involved, such as wearable devices, due to their rigidity and tendency to break under strain.
Innovation Solution
The use of reversibly deformable and mechanically tunable fluidic wires made from liquid metal, such as gallium or gallium-based alloys, which can be injected into cavities within flexible substrates, allowing for deformation without loss of electrical continuity, and the development of connectors with hollow channels to facilitate electrical connections with liquid metal wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solid metal wires are used, then electrical connectivity is provided, but durability and flexibility deteriorate under mechanical stress
Solution Approach 1:
The patent applies hydraulics by using liquid metal (e.g., gallium-based alloys) as a fluid conductor that can flow through flexible tubing. This allows the electrical conductor to deform reversibly under mechanical stress while maintaining electrical continuity, resolving the contradiction between durability and flexibility. The liquid metal can be injected into cavities within flexible substrates, enabling the wire to bend and stretch without breaking like solid metal wires.
Solution Approach 2:
The patent changes the physical state of the conductor from solid to liquid, allowing it to exhibit both durability (maintaining electrical continuity) and flexibility (reversible deformation). The liquid metal's ability to flow and adapt to shape changes while conducting electricity resolves the technical contradiction between reliability under stress and adaptability to deformation.
2Reliability
If liquid metal is used to create fluidic wires, then flexibility and durability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming flexible substrates with integrated cavities that are designed to receive and contain the liquid metal. The cavities are structured beforehand to guide the liquid metal into the desired wire paths, simplifying the manufacturing process. This pre-prepared infrastructure reduces the complexity of injecting and containing the liquid metal during assembly.
Solution Approach 2:
The patent uses nesting by placing the liquid metal conductor inside flexible tubing or cavities within the substrate. This nested structure contains the liquid metal while allowing it to flow freely for electrical conduction. The tubing or cavity walls provide containment and structural support, simplifying the overall manufacturing by integrating multiple functions (containment, flexibility, conduction) into a nested architecture.
3Reliability
If connector designs accommodate liquid metal flow, then electrical integrity is maintained under strain, but device complexity increases
Solution Approach 1:
The patent applies universality by designing connectors that perform multiple functions: they provide electrical connection, accommodate liquid metal flow, and maintain sealing under mechanical strain. The connector structure integrates a hollow channel for liquid metal passage with electrical contact surfaces and sealing mechanisms, reducing the need for separate components and thereby managing complexity while maintaining electrical integrity.
Solution Approach 2:
The patent uses an intermediary approach by introducing a hollow channel or reservoir structure that mediates between the liquid metal wire and the electrical connector. This intermediary structure allows the liquid metal to flow into contact with electrical contacts while maintaining sealing and accommodating volume/pressure changes, thereby maintaining electrical integrity without requiring direct rigid connections that would compromise flexibility.
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 fluidic wires provide enhanced durability and flexibility, enabling reliable electrical connectivity in applications where conventional wires would fail, and the connector design ensures optimal volume and pressure characteristics, maintaining electrical integrity under mechanical strain.
Implementation Method 1
reversibly deformable and mechanically tunable fluidic wires made from liquid metal... allowing for deformation without loss of electrical continuity
Implementation Method 2
the reservoir is to receive liquid metal to substantially fill a volume of the reservoir, the liquid metal extends into the tubular wire casing... the solid metal conductor is conductively connected to circuitry
Data Source
AI summary
A connector to connect to a liquid metal wire includes an opening to couple to a casing of the liquid metal wire and a reservoir, where a portion of a solid metal conductor is positioned within the reservoir. The reservoir is to receive liquid metal to substantially fill a volume of the reservoir and extend through the opening into the fluidic wire, where the reservoir and fluidic wire, when filled with the liquid metal, are to form at least a portion of a liquid metal.